My 960 (170K kilometers) developed a miss suddenly this morning. Reading up in the FAQs, it may be that I need to replace one or more of the coil packs (not necessarily, but I am getting prepared).To that end, I checked some prices today, and I see they range from 120 bucks for all six, to 120 bucks for just one (from Volvo). What is the story here? I understand the old adage that you get what you pay for, but is the quality gradient really that broad?? I mean here is a site that offers all 6 for a low price:
http://www.1aauto.com/volvo-960-s90-v90-ignition-coil/i/1aerk00137?f=526040&y=1997
But Napa has them from 60 bucks to 120 bucks EACH!!! What gives?
Thanks
John D.

Hi jaydee,

At the local Pick and Pull is a 1998 960 / 90 in the miserable hell hole some call St. Louis, Missoui-uh, Yoo Ess Aaaay.

The cowl that covers the spark plug coilover thingies remains in place.

Here's the 960 / 90:

http://row52.com/Vehicle/Index/YV1KS9601W1129179

And the price list, though I did not see how much:
http://www.picknpull.com/part_pricing.aspx?LocationID=68

So, I can ship a set of six to you in Fort St. John BC. Dunno how using USPS and customs comes into it.

And whatever else you may need.

Hope that helps.

Buttermilk MacDuff.
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I switched power amplifiers around and the cde changed from misfire on number three to misfire on number two, so i ordered a new power amplifier from FCP Groton. Can anyone tell me whether the front amplifier is 1,3,5 or 2,4,6?
Thanks
JD

Dear jaydee,

Hope you're well. See reply by Volvo426.

Hope this helps.

Yours faithfully,

Spook

My son had a misfire in his XC70. He has one of those fairly cheap OBD II code readers and it identified the cylinder that was misfiring. He swapped coils with another cylinder and the misfire followed the bad coil. So - proven bad coil, and he replaced it with one from IPD. (ipdusa.com)
--
Bob: Son's XC70, my 83 244DL, 89 745 (Chev LT-1 V8), 98 S90 (recently sold) and 2010 XC60. Also '77 MGB and four old motorcycles

Check the ignition igniter for spark front and rear of intake manifold.
Front one does 135 cylinder rear does 246 cylinder.

Check for spark at the wiring at the top of coil pack to see if getting spark.

You haven't said what is pointing you toward the coils. Try checking the OBD codes first and if nothing, try running a bottle of Chevron Techron in the gasoline before jumping to conclusions.

John

As I tried to indicate in my original message, I am simply looking at available options at this point; nothing is pointing me to either coil pack, plugs, ignition power pack, or atomic transmogrifier. I have simply pulled a code indicating no spark on number 3, and have proceeded no further in my investigation as to what may be causing this code. My question deals only with the justification for the seemingly huge variation of price for coil packs; is there really a difference in quality?
Thanks
John D.

Bad coil pack will trigger CEL. It's more than just a miss. The car will run like crap. I recommend an OBD II scanner to help identify the problem. Gives you plenty of useful information on the 960.

Volvo coil packs can be had for about $55, they are the best IMO.

Hi John D.,

The OEM ignition coils for Volvo 960, 90 -1998 are made in Spain. I'll bet by Bosch. A little bit of research to answer you question. Though I'm trying to find a Bosch PN, and I'll bet, as the form factor is unique, these Volvo 960- 90 series -1998 is a Volvo only part. These are Volvo PN 1275971.

Volvo OEM PN 1275971. Courtesy iPd:


The after market units I've seen are from Taiwan. FCP Euro lists these as made by STI in Taiwan. You may want to research a bit, using different search engines, as search engines can be biased. So a little Google, a little Bing, and little Duck Duck GO.

Volvo OEM PN 1275971. Courtesy iPd:


46$ from Tasca http://www.tascaparts.com/oe-volvo/1275971
62$ from iPd https://www.ipdusa.com/products/9312/120691-ignition-coil-960-s90-v90
55$ from FCP Groton https://www.fcpeuro.com/products/volvo-ignition-coil-960-s90-v90-1275971-1
32$ After market STI https://www.fcpeuro.com/products/volvo-ignition-coil-960-s90-v90-1275971


I've read you can test these ignition coils using a beefier than average multimeter with continuity and resistance function. I dunno the desired resistance range. People at the junkyards will collect these ignition coil over spark plug thingies. They are not so robust as a single oil-filled like that on 240. And grab extra parts like the ignition power stage, sensors, and the such.

960 ignition power stage by Bosch. You have two fo these in 960. iPd courttesy:


See: http://volvowiringdiagrams.com/?dir=volvo/960%20Wiring%20Diagrams

Specifically, the 1997 960 / 90 wiring diagrams. The diagrams indicate ignition stage location and which ignition coils they are connected to.

http://volvowiringdiagrams.com/volvo/960%20Wiring%20Diagrams/Volvo%20960%201997.pdf

PDF page 5

The green books. Dunno the model range.

http://www.k-jet.org/documents/greenbooks/900-series/

Before you replace parts, check the wire harness continuity. Corrosion or a dirty connector, even at the power stage, could cause the problem.

Hope that helps you.

Duffed.
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The power stage I ordered from FCP Groton was on sale for about 150 bucks, down from about 165. In Cdn dollars it will be about $201.
Our local FLAPs is Lordco, much like Napa. Lordco quoted me over 400 bucks Cdn for one power stage!! Anyway, one is on the way from FCP. Too bad, as a friend of mine in Kamloops tells me he has a couple he salvaged from the wreckers, that he would gladly have given me for nothing. Live and learn, live and learn.
Much thanks is due to Spook, Kittysgreyvolvo and others for their research and assistance over the years.
John D.

Well, looks as though I am not out of the woods yet. With the new power stage, there is no change. I still have a miss. OBD said missfire cyl 3, so I cancelled the code, switched the power stages,still missing and CEL on, but no codes will show.
I have tried different plugs, and swapping the coil packs, both of which make no difference.
Almost makes me think that the new Bosch power stage (made in Taiwan) is defective.
JD

So you put the new power stage on the front of the manifold head lite side it does cylinder 1,3,5. Swap it with the rear on and see if the miss changes cylinders if it does faulty power stage. If not see if you are getting spark to coil pack, check the wiring terminal at coil pack they do work loose and fall apart with age.

As I indicated in the previous post, I have tried the new power stage in both front and rear positions, both with faulty results. I have spark to all coil packs.
JD

Should have suggested these checks for you earlier in this thread, jaydee. One has a life case of the perception and cognition myopia. The vision is fine, however. No need for glasses, yet.

http://www.volvowiringdiagrams.com/volvo/960%20Wiring%20Diagrams/Volvo%20960%201997.pdf

Have you pulled spark plugs and checked their condition?

Have you check the condition of each coil pack, or moved coil packs around?

You could be able to test the coil pack condition using a multimeter with a healthy battery set to test both continuity and resistance (ohms).



Using continuity check, first, check across the two (low tension) connector pins of the coil pack. If yes to continuity, then check for resistance (ohms). You should have continuity, yet the correct resistance on across the two pins I do not know. The consistent resistance value you get most may be a guide.

Next, check continuity, and then resistance, between each of the low tension pins and the haute tension side that secures to the sparkplug. Again, I do not know the value should be, so, let the most consistent value be your guide.

You may be getting spark through the harness conductor between each coil pack connector and the:
- Ignition coil relay - serves up 12 VDC B+ through the red / green wire to each of the six coil pack.
- The two Motronic power stages, front and rear, for assigned each three coil packs. Turns ground -0 VDC (negative 12 volts) on and off to power the coil.

You say you switch the ignition control modules from back to front using the two ignition control modules that came on your 1997 Volvo 960.

You surmised a failed Motronic ignition control module. Yet have you swapped the three around with any change in operation. I'll guess no?

Have you pulled the spark plugs in order? Which spark plug does not fire? If you have found that:
- The six ignition spark plug coils check out okay? (Have you swapped these around in an ordered way to trouble shoot a faulty coil? Continuity / Resistance checks.)
- Conductor continuity between each ignition spark plug coil connector and the Motronic ignition control module wire harness connector pinout.

If you don't find fault here, then there may be issue with the wire harness connectors / conductors between the two Motronic ignition power stages and the Motronic ECU. (Disconnect battery, wait, access ECU connector. Back probe connector as assign ECU pin / conductor color and at assign ignition power stage pin / conductor color.

Close inspection of engine bay wire harness connectors and conductor (wire) may help.

So, to put this in an ascending procedure (Well, sort of debatable problem solving order. If I lived in Surrey, I'd be glad to stop in and help, tool boxes and all. You can pint and laugh at the Volvo 240 I never have a garage to park it in.)
1. Check OBD for fault codes.

Any fault codes may help ...

2. Pull coil packs in order. Use a spark plug socket and identify the non-firing sparkplug.

4. NOTE and Interim step procedure: Check spark plug condition. From you written here in this thread, one of the six spark plugs do not fire? Correct? And the same spark plug position? Check gap? What make and model sparkplug do you have? Any indication of sparkplug failure such as bad seal, lost electrode, lost continuity? Perhaps insert a spare known good like sparkplug and fire it up? (You can test a sparkplug for both continuity and resistance.)

If no faults .... yet at a concurrent level in the trouble shoot

5. Swap the ignition coils. (Why I suggest you grab a small handful from a salvage yard.) If the faulty ignition coil may remain faulty on a different spark plug. Yet

If no faults .... yet at a concurrent level in the trouble shoot ... (I'd rather you test the ignition coils before swapping them. Either test can prove an outcome, yet testing the ignition coils is a more proven way to qualify for a failed coil.

5. Resistance / continuity check of ignition coils. When testing between the ignition pack wire harness connector, use tester + VDC probe for the low tension wire harness connector and the the negative at the park plug connector. (New batteries in the tester helps. One with at least a nine volt battery.) Start with the coil connected to the non firing sparkplug.

If no faults ....

6. Check Conductor continuity between each ignition spark plug coil connector and the Motronic ignition control module wire harness connector pinout. Start with the conductors connected to the non firing sparkplug.

If no faults ....

7. Check the wire harness connector / conductor continuity between the two Motronic ignition power stages and the Motronic ECU.

If no faults, the ECU may be in question.

There mere act of disconnecting and reconnecting wire harness connectors can help. Dressing with dielectric DeoxIT helps.

Disconnect the battery before each step. You may opt to reassemble that which you have tested, reconnect the battery, and fire it up.

I hope that helps to further you along.

The line art wiring diagram at the Volvo Wiring Diagrams use essentially useful enough to help you.

http://www.volvowiringdiagrams.com/volvo/960%20Wiring%20Diagrams/Volvo%20960%201997.pdf

PDF page 5. Between and to the right of the two Motronic power stage modules is an illustration of a field coil pickup on the wires near the power stage modules coming from the ECU. I believe this is part of the ignition control sensor that inductively picks up the signal from the ECU to the power stages.

Also, in the diagram, on ignition coil one is a red and whit wire that terminates in a connector to a SERVICE SOCKET CLAMP.

I think that does it.

Questions?

Hope that helps.

What Do I Do Today with Sat-Your-Day MacDuffy's Tavern?
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Hi Kittysgrey, sorry I did not see your reply till today. This afternoon I swapped the alleged bad power amplifier back in, and it made no difference, still same old message "misfire on three" . So on a "what the heck" moment I then cleared the codes,and swapped around coil packes 3 and 4. Lo and behold the code went from cylinder three to cylinder 4! What the heck! When I earlier swapped packs 2 and 3, it made no difference! I must be losing it.....
A friend up in Kelowna is mailing me a few coil packs, amplifiers etc, so I will try them out when they get here.
Many thanks for your indepth description of testing methods etc; you should be writing a book.
John D

I solved the misfire problem today by installing a used coil pack. No misfire, no codes. The original pack was Volvo part number 1275971 and I replaced it with a used one from the wreckers, Volvo part number 9135689. Seems to work well. Any caveats?
John D.

Keep ignition coil spares in the trunk and in the garage? Perhaps more than a full set of salvage yard replacements?

Very pleased that works for you now!

MacDuffed.
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Hi John D.,

Glad that helps you.

I dunno whether I said ignition coils are something to check. I tend to go on so and get mired in the go on and on so narrative.

Probably as you wiggled them coil packs the first time, the about to go faulty one was being cheeky to give you the run around business before it wanted a retirement in a rubbish bin.

Known goof spares are always good to have. To keep in the trunk when you motor to Kelowna or up North to Jasper National Park. Rather write a book in Canada. Hard to get in as a tech writer in Canada.

That 960/90 must be an awesome ride, though.

Thanks for the compliments.

Happy Monday!

Thank you,

Duffed.
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And you use an anti-seize dressing on your spark plug threads?

Use nickel anti-seize. Like Permatex or other brand.

As for torque, well, no more, and probably somewhat less, than spec.
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As I indicated in the previous post, I have tried the new power stage in both front and rear positions, both with faulty results. I have spark to all coil packs.
JD

Dear kittysgreyvolvo,

Hope you're well. The Volvo Pocket Data Booklet - Cars (700,900,S/V90,850,
S/V/C70), 1991-98, shows (p. 56) that the ignition coils were made by Nippon Denso.

For 1996 cars, the Volvo and Nippon Denso units are: #1275971 / #029 700-7990
For 1997 cars, the Volvo and Nippon Denso units are: #1275971 / #029 700-8120.

An on-line parts database suggests these units can be used on all 960s, not just the two years specified in the Pocket Data Booklet.

The MSRP for these coils is about US$71 at a US Volvo dealer.

Hope this helps.

Yours faithfully,

Spook

Hi Uncle Spook,

Thank you.

Though the iPd site indicates Spain as the origin country.

https://www.ipdusa.com/products/9312/120691-ignition-coil-960-s90-v90

Would that be odd, in that the one Volvo PN 1275971 references on of two Nippon Denso PNs? I guess the on-line parts database you mention allows you to make distinction by changing Volvo model year in spite of the same Volvo PN for cross-reference?

I found the Volvo-DataPocket-700-900 on scribd, requiring 9$ for the PDF. I'll keep looking.

Yet I cannot find a price for this Denso Nippon part.

So, using this information ...:

For 1997 cars, the Volvo and Nippon Denso units are: #1275971 / #029 700-8120

... could jaydee find a vendor and make purchase for less, yet it is OEM manufacturer quality?

I don't find much using a search engine.

Thank you.

Sure Happy it's Thursday (all day long)!
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Dear kittysgreyvolvo,

Hope you're well. Nippon Denso likely has factories in many countries, so a "Made in Spain" product shouldn't surprise.

Nippon Denso's on-line catalogue no longer lists ignition coils for Volvos. It may be - and may always have been - the case that Nippon Denso made this item only for Volvo, i.e., that there was never an after-market version made by Nippon Denso.

Hope this helps.

Yours faithfully,

Spook