Is there any way to get new pins/insulators for 2-pin ignition coil connectors

[capkirk123]

I have been looking into fixing the typical disintegrated coil connectors and wire insulation on my 960. I'm too much of a perfectionist for the cheap repair pigtails, and I don't wanna pay for the Barton repair harness. I want to get some nice tefzel wire that'll handle the heat, crimp new pins on either end, and redo the harness so I can have a fresh, unspliced wire from the ignitor modules to the coils.

On the ignitor module side they seem to just be standard bosch 7-way connectors, I can source new pins for those easily, but on the coil side I can't find anything. I can find the connector housings (p/n 9144275), but nobody sells the pins and insulators. I don't want a pre-crimped pigtail, I want to crimp my own wires.

I've found some that look correct on alibaba, but they've got a minimum order of 50 and I'm a little skeptical of the quality. Clearly they're out there, Dave Barton is getting them for his harnesses. Does anybody have any leads? Or should I just go for the 50-pack and start selling my own repair harnesses.

 

[mopar318]

You may be able to eliminate the ignition modules and run a standard S80 or p2 coil pack(3 or 4 pin coil).

 

[capkirk123]

Yeah, that's also an option, but then I'd have to touch the 55-pin engine harness connector (and figure out what pins it uses). Also I read somewhere the dwell is different? Not sure if it's different enough to matter.

 

[dbarton]

I've found some that look correct on alibaba, but they've got a minimum order of 50 and I'm a little skeptical of the quality. Clearly they're out there, Dave Barton is getting them for his harnesses. Does anybody have any leads? Or should I just go for the 50-pack and start selling my own repair harnesses.

I'd be a skeptic too on something from Alibaba until I see it work. And I've seen the crap on ebay too.
Mine have been painstakingly made by my harness builder in Europe for the last 20 years. Since there are no complaints, I'm guessing they're pretty reliable. Better than Volvo original ones, which turn yellow and harden and then disintegrate after a few years of engine heat.

 

[capkirk123]

I'd be a skeptic too on something from Alibaba until I see it work. And I've seen the crap on ebay too.
Mine have been painstakingly made by my harness builder in Europe for the last 20 years. Since there are no complaints, I'm guessing they're pretty reliable. Better than Volvo original ones, which turn yellow and harden and then disintegrate after a few years of engine heat.

The man himself. I don't suppose your builder is willing to give a part number for his pins. Good to know they're more solid than the OEM ones.

You may be able to eliminate the ignition modules and run a standard S80 or p2 coil pack(3 or 4 pin coil).

OK I did some exploratory disassembly and the 55-pin connector came out super easy, I managed to get it unplugged and depinned in 10 minutes. The pins are similar to but not quite Sumimoto pins, I'll have to investigate a little. I found a wiring diagram for the ignition modules too, they're very simple. I think I could very easily do a P2 coil pack conversion if the rest of the harness is that easy, it's just a question of if the Motronic 1.8 ECU will burn them up with too much dwell or something.

 

[ZVOLV]

J-38125 Terminal Repair kit may help

 

[capkirk123]

I have realized at that point I'm not even saving any money. Plus I want this as a road trip car and the road trip in question is rapidly approaching. I'm just gonna buy the repair harness instead of risking breaking something with a custom coil swap.

 

[capkirk123]

Repair harness installed (don't worry, I wrapped the exposed wire after this picture was taken. Ignore the splice that I forgot to put heatshrink on and just wrapped it in electrical tape). Now that all 6 cylinders are consistently firing, the engine runs way better. Nice and smooth idle.

 

[mikep]

J-38125 Terminal Repair kit may help

I have that and then some. I also have the electronic manual.