V90 Ignition Module to Spark Coil pack wiring bundle?

Anybody replace/find/repair any of these?. I think that there are actually two of these (for the 6-cylinder, w/ 3 spark plugs attended by each, which go to the two ignition modules). The problem, which is discussed in the FAQ guides is that the connectors undergo embrittlement due to high heat, causing the connector on the wiring loom/bundle to loose firm contact with the coil pack connectors. I have been unsuccessful in locating replacement cabling assemblies, and am unsure of where to find replacement connectors that I might use to rebuild the current cables. Mine do not look very good anymore and I am getting a repeated check engine light that indicates misfire due to loss of electrical contact. My local brick dealer was uncharacteristically unhelpful, saying that the only part purchase that would provide new connectors was the complete wiring harness at about 4K US$. Thoughts?

Oops, found this on the FAQs which may give me a lead. Anybody else dealt w/ this prob? Coil Pack Connectors: [Tip from Rafael Riverol] If you have a 960, I please take off the plastic cover atop the engine that reads "24 valves" and examine the female connectors at each of the six coils. I suspect you will likely find crumbling insulation, brittle barrels and poor connections. I can tell you these can fail you anytime. You will also likely find crumbling wire sleeves that will allow wire chaffing againt the engine head. Parts Source: [John Randstrom] Borton Volvo gave me this Volvo part #3523813 (List $6.10ea, net $2.76) as the replacement ignition coil female terminals for my '93 960. These have the rubber isolators on them. You need two per housing. The connector socket housing Volvo part # 9144275-6 is $1.25 Experience with Radio Shack and other sources is not good: the female connectors de-tension and fail to maintain contact.

Hi, I was looking into this as I suspect the wiring and/or connector does - over time - become less conductive and could give rise to occasional misfires. The quote for the loom was "interesting"!!! but they sell the connectors and the clips etc so that you could theoretically rewire the part under the cover withe the bits and some new wire. Just a matter of tracing out the cables to an appropriate point to cut new cable in... Des. . . ;)

Hello there, Des! I think that you are spot on. Although copper wire does not lose conductivity over time, connectors conductors oxidize, resulting in higher resistance, hence higher I2R losses, therefore more heat, therefore accelerated heat breakdown. Additionally, wiring connector plugs, typically made out of plastics and various rubber compounds tend to break down due to heat over time, both engine soak heat and electrical resistance heating. The latter is what gets most electrical connections, regarding heat. My spark plug coil pack connectors under the "24 Valve" dust cover are in the advanced stage of heat-induced degradation. I do not intend to perturb them again until I have some replacement parts in hand. I agree with your suggested method of repair: cut out and replace the old bad connector with the repair jumper, locating the splice joint under the '24 Valve' cover. I don't intend to perturb the multi-conductor connection to the ignition modules, meaning that the splicing repair will be required to be performed on the top of the engine. More details when I get around to the repairs.

Wow, Des. I just clicked on your Volvo RWD link. I am absolutely stunned by your work! And your V90 (blue) is IDENTICAL to mine (actually my college-aged son's). I want your spoiler!

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Update: Today I was in the general area of the only Volvo dealer on the islands, where resides Kanoa, the ultimate parts finder at the parts counter. This guy takes it as a personal challenge to be able to find any part. I told him V90 spark plug coil connectors and he produces 6 bare connectors (at about $1 US ea) and one dozen push on terminal connectors with wire pigtails on them. Cool. This weekend I may try to knock out this job. Shouldn't be too tough. I'll take pics and try to figure out how to post them (computer idiot, me).

Easy Rhino.. go here Dave has all the answers to your problems Regards Michael

HI, Holy thread resurrection! Des. . .;)