home register FAQ memberlist calendar

Go Back   Turbobricks Forums > Mechanical > maintenance & nonperformance

Reply
 
Thread Tools Display Modes
Old 09-19-2022, 01:52 PM   #1
bronze mettle
Newbie
 
Join Date: Sep 2022
Location: Portland, OR
Default Ignition harness plug to ICU

I've been searching and haven't found any information on this other than things like, "that connector is tricky.."
I have an 84 244GL LH 2.0, replacing the engine and ignition wiring harnesses with new from Dave B, all going well until i get to the ICU connector that Dave informs us are not made anymore and must be reused.
He goes into detail on how to reuse these plugs but as far as I can tell, the plug i've got is the exception to the rule. He's out of town until the end of the month or I'd be messaging him about it. It's the older plug style, without weather seals, and seems like the wire terminals/plug are pull-to-seat and that the terminals won't be able to come out the back as Dave says. But i also can't get them to budge out the front or even twist in the connector. They're totally seized.
Tried a junkyard for another plug, only one i was able to get has the exact same problem. I'm at a loss as to what to do next. Any help or advice or direction anyone can point me in would be really helpful.
thanks very much.

-B
https://postimg.cc/gallery/sxpTZgz
bronze mettle is offline   Reply With Quote
Old 09-19-2022, 03:29 PM   #2
wht_245wagoon
Board Member
 
Join Date: Mar 2016
Location: Escondido, CA
Default

I don't know if these would work, they might have the tool to remove the wire connection from the plug. I haven't seen that type of plug. Sorry couldn't be more help.

https://www.amazon.com/dp/B0922GF9W8...2-587d01f975e8
wht_245wagoon is offline   Reply With Quote
Old 09-19-2022, 03:30 PM   #3
Khrrck
Professional Amateur
 
Join Date: Mar 2015
Location: Beaverton, OR
Default

Quote:
Originally Posted by TheMenaceSD View Post
I don't know if these would work, they might have the tool to remove the wire connection from the plug. I haven't seen that type of plug. Sorry couldn't be more help.

https://www.amazon.com/dp/B0922GF9W8...2-587d01f975e8
It looks like the issue is that the back end of the plug is sealed, preventing the connectors from being pulled out the back.

I see two Philips screws on the plug - any chance they're holding it together clamshell-style?
__________________
'87 240 budget wagon. Sadly departed.
'88 240 eggshell wagon.
Quote:
Originally Posted by Dirty Rick View Post
Navigating the Siskiyous in a 3 wheeled Volvo will not end well.
Khrrck is online now   Reply With Quote
Old 09-19-2022, 03:44 PM   #4
bronze mettle
Newbie
 
Join Date: Sep 2022
Location: Portland, OR
Default

thank you for the replies!

Quote:
Originally Posted by Khrrck View Post
It looks like the issue is that the back end of the plug is sealed, preventing the connectors from being pulled out the back.

I see two Philips screws on the plug - any chance they're holding it together clamshell-style?
you're right about it not being pulled out the back. the holes the wires come out of aren't even big enough for the terminals to come out. And the metal terminals themselves have barbs that face forward. I suspect when the harness was manufactured the wires were pulled through from the back and out the front where the terminals were crimped on and then pulled backwards to seat into the plastic plug. i've bent those front facing barbs inwards so they can't prevent the terminals from moving back out the front but they're stuck in place. i imagine heat cycles and 40 year old grease have just got them stuck in place.

unfortunately those philips head looking things are just part of the plastic molding that fit into the corresponding seats in the mating side of the other half of the connector. you might be able to see them in the photos but they're small. each side of this connector has a separate volvo part number: 4055413 and 4055414

Still at a loss for what to do beyond finding the newer style connector with the weather seals.
bronze mettle is offline   Reply With Quote
Old 09-19-2022, 05:10 PM   #5
Fa182
Stage 1
 
Fa182's Avatar
 
Join Date: Apr 2016
Location: Austria
Default

I believe the connector is still available from GCP (if that's the right p/n).
Only thing, it has the whole harness attached

https://www.gcp.se/en/products/3515723-2/
__________________
Fa182 is online now   Reply With Quote
Old 09-19-2022, 05:33 PM   #6
bronze mettle
Newbie
 
Join Date: Sep 2022
Location: Portland, OR
Default

well this is a suitable option if i can't get my hands on an alternate plug or sort out some way to free this one of the old wiring/terminals. thanks for the info, i'm going to email gcp and see if they can source a plug for me.
bronze mettle is offline   Reply With Quote
Old 09-19-2022, 06:30 PM   #7
Khrrck
Professional Amateur
 
Join Date: Mar 2015
Location: Beaverton, OR
Default

Oh I see now, in the final photo the connector is split in half.

Have you given it a good soak in contact cleaner to possibly loosen up some of that 40y/o grease and glue? If you have replacement wires and terminals, a metal pick might be able to free up the back end a little...

Barring getting them out or finding a replacement (NOS or nice used), your best bet may be taking some really good measurements and getting something compatible printed out of ABS...
Khrrck is online now   Reply With Quote
Old 09-20-2022, 07:46 AM   #8
apollokid
Board Member
 
apollokid's Avatar
 
Join Date: Aug 2020
Location: Milan (Italy)
Default

Quote:
Originally Posted by TheMenaceSD View Post
I don't know if these would work, they might have the tool to remove the wire connection from the plug. I haven't seen that type of plug. Sorry couldn't be more help.

https://www.amazon.com/dp/B0922GF9W8...2-587d01f975e8
I bought them on aliexpress for much less a lot of years ago and they work great.
Very usefull to open the connectors without damage.
https://it.aliexpress.com/item/32840338073.html
apollokid is offline   Reply With Quote
Old 09-20-2022, 11:31 AM   #9
bronze mettle
Newbie
 
Join Date: Sep 2022
Location: Portland, OR
Default

Quote:
Originally Posted by Khrrck View Post
Have you given it a good soak in contact cleaner to possibly loosen up some of that 40y/o grease and glue? If you have replacement wires and terminals, a metal pick might be able to free up the back end a little...

Barring getting them out or finding a replacement (NOS or nice used), your best bet may be taking some really good measurements and getting something compatible printed out of ABS...
I have replacement wires and terminals. I've tried soaking everything for 24 hours to no avail. I sourced one of these plugs from a junkyard that's in the exact same shape and i've nearly destroyed one of them trying to extract the wiring and terminals, similarly to what you described.

GCP emailed me back and said they don't have that part in stock.

I think my only sure bet right now is to get one printed as you've suggested. unless a later model pops up at the junkyard and i get to it before someone else.

thanks for your support and ideas.
bronze mettle is offline   Reply With Quote
Old 09-20-2022, 11:33 AM   #10
bronze mettle
Newbie
 
Join Date: Sep 2022
Location: Portland, OR
Default

Quote:
Originally Posted by apollokid View Post
I bought them on aliexpress for much less a lot of years ago and they work great.
Very usefull to open the connectors without damage.
https://it.aliexpress.com/item/32840338073.html
thanks for your idea and resource, and all the way from Milan! unfortunately i have similar tools and they haven't been able to help with this particular plug situation.
bronze mettle is offline   Reply With Quote
Old 09-20-2022, 12:22 PM   #11
Khrrck
Professional Amateur
 
Join Date: Mar 2015
Location: Beaverton, OR
Default

Quote:
Originally Posted by bronze mettle View Post
unless a later model pops up at the junkyard and i get to it before someone else..
Well, you're in Portland, so probably one of the best places to get spare parts from the dismantlers around here. Unfortunately I don't know what would be compatible. You could try messaging 2manyturbos (closest one that I know of) and asking if it's something he has or knows how to substitute.
Khrrck is online now   Reply With Quote
Old 09-20-2022, 01:17 PM   #12
dl242gt
Old and boxy but good.
 
dl242gt's Avatar
 
Join Date: Jun 2002
Location: S NJ, a suburb of Phila.
Default

There was a Volvo repair and parts place called Red Block Performance in the Portland area. I never dealt with them but have watched their videos on Utube. Had lots of parts and said to call with your needs.
__________________
Dave,
1982 242 turbo. 338k miles. MVP/ BNE coilovers and 3" exhaust. Flowed 405 with a V15T. Cossie turbine housing with upgraded compressor housing. With wildly uncontrolled wastegate. 90+, IPD remote oil filter. Some other goodness, too. Restored in 2k. Now ready for a 2nd restoration.

1993 245 Classic, 440k miles, enem V15. IPD bars and chassis braces. Simons sport exhaust from Scandix. sbabbs ezk chip. Been a good road warrior. Genuine Volvo rebuilt leaky M47.
dl242gt is online now   Reply With Quote
Old 09-20-2022, 03:17 PM   #13
apollokid
Board Member
 
apollokid's Avatar
 
Join Date: Aug 2020
Location: Milan (Italy)
Default

@bronze mettle

May be the connector is printed like commercial plugs?
I've opened similar connectors by using the tool that seems a big round pin.
The first one to remove is generally more difficult since you have to understand how to use the tool and to unlock the little tab.
Obviously all I say works only if the connector is openable and not printed.

On aliexpress generally you can find also near every kind of pin replacements and the crimping plier with all kinds of special jaws (i've rebuilt with success the Bosch 25 and 35 pins connectors in this way when I built my ECU breakout boxes but I opened also many other plugs)
apollokid is offline   Reply With Quote
Old 09-20-2022, 03:53 PM   #14
Khrrck
Professional Amateur
 
Join Date: Mar 2015
Location: Beaverton, OR
Default

Wild idea - you could slide the connectors in place over the socket pins (with no plug housing), fill the thing with epoxy or silicone (preferably sealing off the backside, etc so it doesn't get inside the housing) and splice in a proper connector further up the harness.
Khrrck is online now   Reply With Quote
Old 09-20-2022, 04:13 PM   #15
bronze mettle
Newbie
 
Join Date: Sep 2022
Location: Portland, OR
Default

Quote:
Originally Posted by Khrrck View Post
Well, you're in Portland, so probably one of the best places to get spare parts from the dismantlers around here. Unfortunately I don't know what would be compatible. You could try messaging 2manyturbos (closest one that I know of) and asking if it's something he has or knows how to substitute.
yeah i'm hoping so. only a few 240s at the south portland pnp and one in sherwood, right now. just checking the inventory twice a day. thanks for the direction to 2manyturbos, i'll message them next
bronze mettle is offline   Reply With Quote
Old 09-20-2022, 04:14 PM   #16
bronze mettle
Newbie
 
Join Date: Sep 2022
Location: Portland, OR
Default

Quote:
Originally Posted by dl242gt View Post
There was a Volvo repair and parts place called Red Block Performance in the Portland area. I never dealt with them but have watched their videos on Utube. Had lots of parts and said to call with your needs.
thanks Dave i'll try this out!
bronze mettle is offline   Reply With Quote
Old 09-20-2022, 04:16 PM   #17
bronze mettle
Newbie
 
Join Date: Sep 2022
Location: Portland, OR
Default

Quote:
Originally Posted by Khrrck View Post
Wild idea - you could slide the connectors in place over the socket pins (with no plug housing), fill the thing with epoxy or silicone (preferably sealing off the backside, etc so it doesn't get inside the housing) and splice in a proper connector further up the harness.
not a bad idea at all. i'll keep this in mind!
bronze mettle is offline   Reply With Quote
Old 09-20-2022, 04:31 PM   #18
white855T
Board Member
 
Join Date: Sep 2013
Location: Dallas,TX
Default

Quote:
Originally Posted by bronze mettle View Post
yeah i'm hoping so. only a few 240s at the south portland pnp and one in sherwood, right now. just checking the inventory twice a day. thanks for the direction to 2manyturbos, i'll message them next
You just need to check from Tuesday to Friday for inventory. Cars are always put out on Monday. You can use row52.com. New inventory will always show up listed the next day. Sometimes new cars are set on Friday but not that common. If it were the case, they'd show up listed on Saturday.
white855T is online now   Reply With Quote
Old 09-20-2022, 06:06 PM   #19
bronze mettle
Newbie
 
Join Date: Sep 2022
Location: Portland, OR
Default

Quote:
Originally Posted by white855T View Post
You just need to check from Tuesday to Friday for inventory. Cars are always put out on Monday. You can use row52.com. New inventory will always show up listed the next day. Sometimes new cars are set on Friday but not that common. If it were the case, they'd show up listed on Saturday.
Thanks for the heads up! I’ll keep my eyes peeled.
bronze mettle is offline   Reply With Quote
Old 09-20-2022, 06:16 PM   #20
Khrrck
Professional Amateur
 
Join Date: Mar 2015
Location: Beaverton, OR
Default

Quote:
Originally Posted by bronze mettle View Post
not a bad idea at all. i'll keep this in mind!
Just be aware that it'll be unrepairable should it fail again later.
Khrrck is online now   Reply With Quote
Old 09-20-2022, 06:19 PM   #21
rb92673
Board Member
 
Join Date: Jan 2017
Location: San Clemente
Default

Why not replace the entire plug on both sides? I like DEUTSCH DT connectors.
rb92673 is offline   Reply With Quote
Old 09-20-2022, 07:21 PM   #22
Khrrck
Professional Amateur
 
Join Date: Mar 2015
Location: Beaverton, OR
Default

Quote:
Originally Posted by rb92673 View Post
Why not replace the entire plug on both sides? I like DEUTSCH DT connectors.
OP says "plug to ICU" which to me implies that the other end is built into a component.

If both ends are on harnesses then yeah, just replacing both ends sounds like an even better option.
Khrrck is online now   Reply With Quote
Old 09-21-2022, 02:55 AM   #23
bronze mettle
Newbie
 
Join Date: Sep 2022
Location: Portland, OR
Default

Quote:
Originally Posted by Khrrck View Post
OP says "plug to ICU" which to me implies that the other end is built into a component.
spot on.

wish it was a plug somewhere else in the harness
bronze mettle is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


All times are GMT -4. The time now is 04:35 PM.

Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2022, vBulletin Solutions Inc.