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Coil receptacle extraction tool V70-XC70 2000

posted by  Robert S. on  Sun Feb 17 10:22 CST 2019
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last visit: Sun Sep 21 05:48 CST 2014
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Been chasing this ignition troubleshooting problem for a while, a misfire on cyl. #3 which was finally isolated to intermittent continuity in the #3 coil receptacle housing. (Eliminated possibilities of low compression, faulty coil, faulty spark plug). See:

https://www.fcpeuro.com/products/volvo-plug-housing-9456341

https://www.fcpeuro.com/products/volvo-ignition-coil-connector-housing-genuine-volvo-9494800#fitment

Does anyone know what the proper terminal extraction tool is, so I can transfer a new receptacle housing to the existing #3 ignition wire harness? (Four separate wires/terminals connect to the receptacle housing).

Current status: every few thousand miles #3 will misfire again. After disconnecting the receptacle housing from the coil, blasting the connectors with electrical cleaner spray and filling coil and contact cavities with dielectric grease, continuity is reestablished for a while and misfire goes away. My diagnosis is that the terminals are worn/corroded inside the receptacle housing - it's time for a new one (links above).









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    Coil receptacle extraction tool V70-XC70 2000

    posted by  Chris Mullet on  Mon Feb 18 13:39 CST 2019
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    last visit: Fri Oct 24 09:08 CST 2014
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    Rather than purchasing the special purpose contact extractor, which can be quite pricey, I use a tiny-tiny screwdriver tip to slide in beside the contact to depress the locking tang (red circle). Then the contact can be pulled free by tugging gently on the wire or by using needle nose pliers. By tiny I mean one of those that aren't much larger than the ones you tighten your eye glasses with.

    Sometimes there is a locking tang on BOTH sides of the contact, necessitating the use of TWO tiny screwdrivers simultaneously. Although yours will probably look different than this photo, the principle is the same. Red arrow depicts which direction to insert the screwdriver and the blue arrow depicts which direction the contact is extracted from the connector.


    --
    Current rides: 2018 Volvo S60 Inscription (What the heck do all these buttons do?), 2005 Volvo S80 2.5T (Soon to go bye-bye), 2003 Volvo V70 2.4NA (The family "truck"), 1973 Volvo 1800ES (STILL not road worthy!)








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      Coil receptacle extraction tool V70-XC70 2000

      posted by  Robert S. on  Tue Feb 19 07:39 CST 2019
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      last visit: Sun Sep 21 05:48 CST 2014
      [RELATED]

      That's a great tip, thanks. Since I've mangled my share of repinned connectors all the way back to RC car and boat days, I may try to eventually find the correct terminal removal tool for these coil connectors.

      This will likely become a required skill set for those with aging cars and COP ignition systems. What's telling, neither of the two Indy shops who work on Volvos for a living even considered this symptom/repair. Both shops were ready, after OK compression checks, to replace spark plugs and swap around and replace ignition coils. The coil connector problem was never discussed by the shops and one which I isolated myself.







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        Coil receptacle extraction tool V70-XC70 2000

        posted by  Chris Mullet on  Tue Feb 19 09:19 CST 2019
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        last visit: Fri Oct 24 09:08 CST 2014
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        Robert,

        So I guess you're looking for this sort of extractor:

        https://www.alliedelec.com/product/te-connectivity/1-1579007-6/70089979/

        I gotta admit it would be nice to have. It looks like you first insert the two outer legs into the connector to depress the the locking tangs. Then you push some sort of lever or slider that extends the inner two legs which push the contact out of the connector. According to the detail drawing the whole tool is only ~107 mm in length.

        The big question is which extractor is required for the Volvo coil connectors? Does a person have to have a toolbox full of $75 extractors in order to service any type/size of connector they are confronted with?
        --
        Current rides: 2018 Volvo S60 Inscription (What the heck do all these buttons do?), 2005 Volvo S80 2.5T (Soon to go bye-bye), 2003 Volvo V70 2.4NA (The family "truck"), 1973 Volvo 1800ES (STILL not road worthy!)








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          Coil receptacle extraction tool V70-XC70 2000

          posted by  Robert S. on  Sat Mar 2 19:40 CST 2019
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          last visit: Sun Sep 21 05:48 CST 2014
          [RELATED]

          Update, hopefully the final one.

          Went ahead and purchased a new receptacle housing Volvo p/n 9494800. (Note: through research in various parts suppliers found that Volvo p/n 9456341 is the same part).

          And,

          Purchased the correct terminal extraction tool; I found this "Rennsteig" tool on Amazon, about $37. Key words when searching for the correct tool: "for Junior Power Timer connectors." See equivalent part numbers on the plastic tool storage box.

          The new Volvo receptacle housing was installed on Cylinder #3, and the terminal extraction tool is exactly what's required to pull the four wires from the old housing and insert them into the new housing.

          From looking at the old receptacle housing, the top plastic clamp had lost its tension and apparently allowed the housing to move inside the ignition coil port, causing arcing and wear on the contact blades. The blades were burned and damaged; and the coil no longer would fire. Replacement coil and the new receptacle housing has fixed the #3 misfire, hopefully for good. Included below are a few pics.







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            Coil receptacle extraction tool V70-XC70 2000

            posted by  KlausC on  Sun Mar 3 10:46 CST 2019
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            last visit: Fri Oct 24 10:15 CST 2014
            [RELATED]

            Two barbed connector. Two small screwdrivers will also work for removal.

            Nice writeup!
            --
            Keeping it running is better than buying new








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          Coil receptacle extraction tool V70-XC70 2000

          posted by  KlausC on  Tue Feb 19 10:16 CST 2019
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          last visit: Fri Oct 24 10:15 CST 2014
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          I have used the screwdriver technique successfully many times. It does take a toll on the plastic part, and a couple of bandaids when the screwdriver 'slips'. Just don't hurry.
          --
          Keeping it running is better than buying new








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            Coil receptacle extraction tool V70-XC70 2000

            posted by  Chris Mullet on  Tue Feb 19 11:35 CST 2019
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            last visit: Fri Oct 24 09:08 CST 2014
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            Ha! I hear ya. It's a bit tricky when there are TWO barbs that need released - one screwdriver in each hand and then pull the wire with your teeth.
            --
            Current rides: 2018 Volvo S60 Inscription (What the heck do all these buttons do?), 2005 Volvo S80 2.5T (Soon to go bye-bye), 2003 Volvo V70 2.4NA (The family "truck"), 1973 Volvo 1800ES (STILL not road worthy!)








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              Coil receptacle extraction tool V70-XC70 2000

              posted by  KlausC on  Wed Feb 20 14:35 CST 2019
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              last visit: Fri Oct 24 10:15 CST 2014
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              You forgot about the part where you have to nail down the plastic connector to the work bench.
              --
              Keeping it running is better than buying new








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    Coil receptacle extraction tool V70-XC70 2000

    posted by  KlausC on  Sun Feb 17 20:22 CST 2019
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    last visit: Fri Oct 24 10:15 CST 2014
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    I have never seen one come apart. Does the orange band come off? And the two halves come apart at the rear? It should be something easy to do, think about the factory workers.
    --
    Keeping it running is better than buying new







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