So as a I previously mentioned in my first post, the 960 needs a lot of work. Currently it is driving on 5 out of its 6 cylinders and has oil and grime all over the engine bay. One of the first things I did was check the Idle Air Module. This piece regulates the air when the car is idling (as the name suggests) to give the engine a smooth idle at the low RPMs. Unfortunately, their design means that over time they can become filled with oil and grime which causes them to stop working. Checking the full intake system made sense as the parts are easy to access and can usually benefit from a cleanup on any car.
Most of the intake system comes off with a simple screw driver. Most of the system is actually tool-less removal and uses latches to attach everything together. The intake filter seemed to be in decent shape, however the main concern was around the throttle body. Due to the old gasket on the oil cap, oil leaks from the top of the engine down onto a lot of components. I suspect this oil is also the reason for the misfire on cylinder 3. I made sure to clean the throttle body, as well as check the Idle Air Module, as well as inspected the MAF for any buildup.
The gasket of the oil cap can go bad on the 6cyl motor, leading to oil build up around the cap and pooling along areas of the head. The oil from the cap has been leaking significantly, there is buildup around the intake and even the throttle body.
Additionally, while I was in the engine bay I made sure to check the belts. The motor on the 960 series cars use an interference design, meaning that the timing belt is crucial to the operation of the engine. Without the belt, the pistons will rise on the combustion stroke and collide with the stuck open valves since the belt controls when the valves open and close. Unfortunately, the sticker for the last timing belt replacement on this car dates back to 2006 when the car had significantly less miles. I assume that it has been replaced since then since the service interval for the belt is around 40-50k miles.
Not the information you want to see on a car in 2019 with 190k miles on the ODO.
While the timing belt may not look terrible upon my brief inspection, I would HIGHLY recommend that any new 960 owner do the maintenance on it. I plan on using IPDs kit with a new belt, pulleys, and tensioner as any of these components going bad can cause a catastrophic failure of the motor.
The last fix I did in my initial dive into the car was physically checking the connections around the intake system. Upon my inspection the MAF was very clean and the connectors seemed to be in solid shape. However, on the Idle Airflow Module, I found nasty corrosion that could have been causing issues. I used a can of electrical contact cleaning to remove the corrosion as well as a small pick to clean out any stubborn bits. The female end of the plug on the IACM was also cleaned for good measure.
I apologize that this write up was a bit short, I am writing it many days after I have done the work. For much of my writing, I find it easier to explain my work and processes when it is fresh in my mind and I can dive deeper into the repairs. In part 2 I will be covering the diagnosis of the misfire, and my continued work to resolve it.
