Hello-

My '01 Volvo S40's check engine light came on and has been sputtering constantly. When this happened in '09 I replaced my spark plugs and everything was fine.

I didn't have time to change the plugs myself so I took it to my mechanic and he replaced my plugs; however, he told me that the electrical connectors at the coil need to be replaced. I asked him to explain further and he described my need for a two-pin female connector to attach to each coil. I need two sets of these.

Can anyone help me find the specific part name or number? Any advice about what I would need in all to fix this issue? I cannot find this in my Haynes book and would like to fix this before the brutal NY winter.

Thank you!

Aaron

1986 Volvo 240 DL
1991 Volvo 240
2001 Volvo S40

 

Are these "female electrical connectors" part of a larger part that I can buy from Volvo?

 

Hey aj, I have a similar issue on my 2000 S40. The female connectors for the ignition coils are just really broken down and falling apart. I'm surprised they stay put on the coils and supply them with power.

I checked into it a while ago because I thought it might have been a good thing to fix and make new again. I talked to a dealer and it took a long time for the guy on the phone to understand what I was talking about. Ultimately he told me that if I wanted to replace those, I'd have to get an entire new engine wiring harness. Apparently it's an all or nothing deal. I can't help but believe the guy was right since I see no way of replacing a single plug if it breaks. Silly design.

The wiring harness is an expensive part and will probably cost quite a bit in labor too since it involves routing all the wires correctly. I wouldn't want to do it myself, and consequently I never had it fixed.

Hope this helps!

 

Ran into this problem myself some days ago.Ended up pulling the wires out with the terminals on them.Probably will just silicon it into place but it is pretty secure as it is now.
PS: 5 years in my plugs did fall apart.I did find that the blinkers on the fenders has the same plug so I went to the junkyard and got some.Spliced them up and all is good.Doesnt get any cheaper and simpler than that.PH1 and 2 the same.

 

Thank you AGShear-
The wiring harness seems to make sense. I had the same problem trying to explain what I needed to various salvage yards and Volvo mechanics. It does seem like a silly design. My female connectors are completely corroded from heat and the elements, and it sounds like it will be going back to the $$$ mechanics.

GerBeGurGya- Please let me know if you have success putting silicon on them. Will the silicon stand up to that intense heat? I am leaning toward replacement of the wiring harness, as I am relying on this beast for several more years. I hope that my S40 will run as long as my Swedish bricks did, but I have my reservations. They don't make them like they used to!

If anyone can extend their experiences and/or expertise in this area, it would be greatly appreciated! Thank you to those who have responded!

 

I have read on different forums that this wiring system connects the firewall to coils...is this accurate? It appears that many other S40 owners are looking for this set-up as well.

I would be interested in purchasing this if anyone has a salvaged '00-'04 S40.

Thanks again!

 

hello all
Did any body ever come up with practical and inexpensive solution to this issue?
I have an 01 s40 with same problem. Any insight or practical solution is very much appreciated.
thanks

 

Hi everyone,

It appears I've found a solution to this problem. I'm currently attempting to sell my '00 S40 and was having a really hard time doing so with these broken-down connectors. I'm not about to pay Volvo $1,400 + labor for a new wiring harness, either.

Here's a link to where you can purchase replacement connectors: Black Vinyl Wire Cover Tubing for Wire Harnesses

I needed 2x replacement female 2-pole plastic shells and 4x female bullet terminal wires. I'm having my mechanic splice the wires into place with the old ones and adding the new plastic shells to protect and hold the wires in place. Total cost parts $32. My guy's labor will be ~$30, but your mileage may vary.

I hope this helps someone because it's been a problem that's plagued my dear Volvo for over 2 years now.

 

I know it's an old thread but this just happened to my 2002 s40 and my mechanic said i need to get the harnesses so would those work for my situation as well? I would need the wires to splice as well I am assuming? I'm adding a photo of what I need.
Thanks in advance for any info I can get.

 

dealer part numbers can be found by using some online dealer stores - check out volvopartswarehouse.com and tascaparts.com otherwise you may want to see if a local yard will sell you a harness or let you clip and splice with some shrink tubing to seal it up.

 

Thanks so much! I'm on with tasca now.

 

I have been having this issue off and on the last couple of years. My mechanic gave me the same option to purchase the entire electrical system from volvo for 1200$ or have them jimmy rig it. The picture below shows what they did which held for about 2 years but isn't anymore. I'm looking around my area for a used part or junk yards to get the part replaced. Mine is a 2003 s40 and I was wondering if there are any other years that are compatible? Also does anyone know what this part number would be?

 

2001-2004 should work. Needs to have the lead for the vvt solenoid.


Full harness is 30864977 I got mine on tasca. http://www.tascaparts.com/oe-volvo/30864977

I'm not 100% but I believe these to be the individual plugs - http://store.voluparts.com/9144275-socket-connector/

 

Well jalopy jungle had a '00 and '01 s40. The 01' someone had cut the coil harness so I was pretty bummed. I found out that the '00 has the same part though so I got the issue fixed. 3 dollars well spent!

 

Hi all,

I am magically still subscribed to this thread years later, so I figured I'd weigh in. I'm no longer a Volvo owner, but prior to selling my 2000 S40 last year I finally found a solution to the issue experienced with the wiring harness. You can purchase the individual plugs from Dave Barton, who runs a Volvo repair site.

Here's the link to the purchase page: Wire Harnesses Repair Parts and Connectors

For each plug that's falling apart, you'll need to purchase 2x female wire pigtails and 1x female 2-pole connector housing. Any mechanic should be able to splice the pigtails in, heat-shrink wrap them up, and your ignition coils should work like new. If I recall correctly, the whole repair cost me under $75 including parts and labor.

Hopefully this helps someone out! As for me, I've since moved on to a leased vehicle and can't see myself going back.