Hi guys,

I have been lurking for a while, just recently bought a 91 240 and everything has been decent so far. I think I have dun goof'd though.

I push the spark plug wire by the boot to get it to click onto the plug but it never happened. I looked inside and noticed the contact is further down than the others that click nicely without much force. These wires are brand new so I'm hoping there is a way to re adjust the boot so the contact isn't so far down.

I have been trying to pull the wire boot back so that the contact can snap on the plug again but it is so difficult. It's nearly impossible to get leverage. Anybody have any ideas for this? I know it was a stupid mistake to push on it too hard but now I'm trying to fix it.

I thought about using needle nose pliers to pull on it from the other end so I can get the boot back but I don't want to damage the contact. Any feedback is much appreciated.

 

what brand are these spark plug wires? theres a lot of junk sold out there, the best ones I've found for these volvos are the bougicord sets, which are virtually OEM quality.

note that some sets require the 'nut' on the tip of the spark plug to be removed so they go onto the threads directly, while others require that nut to be there and clip onto the nut.

 

I actually did get the decent bougicord set from FCP. The wires are great it's just.... I don't know how to pull the boot back into it's correct position due to leverage limitations.

I tried shoving the wire back in from the other end (even had some dialectic grease on there for lubrication) but that's sketchy because it could get damaged if it's bent too much.

As far as I can tell all I really need to do is pull the boot back into it's original position. But since the wires are so new the boot is too snug. Maybe I'll post some pictures to help clarify my issue.

 

Apply, spray, some lubricant such as silicone on the wires, then you can slide that boot more easily.

 

This shows the plug all the way in the boot without a connection.



This shows the wire with the issue, you can see contact is super far down.



Final image shows correct position of the contact of a wire that snaps easily.



Thanks, I'll head out and grab some spray hopefully that will do the trick.

 

I think I might be screwed, I tried using some wd40 because I had it around and it's impossible to move the boot without damaging the wire. I might just have to buy new wires... what a waste.

There has to be some way.

 

They make a spark plug pliers that you grab the wire with. Spray the top of the boot where the wire goes in with wd40 . Grab the boot with one hand and the wire with the pliers . Push hard the wire into the boot. I've done this before.

 

I will definitely give this a shot. Are these the pliers you speak of?


If not can you link me the relevant item? THANKS!

 

Yep , that's the type.

 

Alright, so I didn't want to wait for the spark plug wire pliers so I got some janky plastic ones from Pep Boys. Needless to say it was a POS and I just ended up using latex gloves and some marvel mystery oil to man handle them back in. Eventually got them back to the right spot and everything is fine now.

Thanks for the help guys.