'01 S40 oil on spark plugs

[ajattridge]

Good evening,

I will apologize in advance for the long post and THANK YOU all for sharing your knowledge.

I am losing my hair with my 2001 Volvo S40. My CEL popped on with accompanying sputtering/loss of power. New spark plugs fixed a similar issue in 2009 and I thought that if I would just replace the plugs, I would be all set. Wrong.

Didn't have time to fix it myself this time so I took it to a shop who does work on my buddy's 2000 V40 and had good reviews. His diagnostic test read P0304 (cylinder #4 misfire) and he replaced my plugs as I asked. According to the mechanic, my plug wires and coils were OK.....HOWEVER.......he told me that the "wiring harness" that connects to the ignition coils is corroded and needs replacement, adding that Volvo doesn't sell this wiring as a replacement part. He added that my car will continue to sputter until those "electrical connectors at the coil" are replaced. To quote his estimate I need the "electrical, female connectors to attach to each ignition coil". Does this make sense to any Volvo mechanics or handymen out there? I have not had luck locating these wires online or over the phone, or even figuring out what the heck it is I need to fix this!!!

I made the mistake of not checking the mechanic's work after getting my car back 3 weeks ago. Just an hour ago I popped the plastic engine cover off and desired to inspect my plugs/wires/coils/wires myself, just to gain a better understanding of what I exactly need to replace. What I have discovered is my WORST NIGHTMARE! Not only is the area where the plugs are covered with bits of crumbled plastic from the corroded wire housings, but there is a substantial amount of OIL pooled up in the nooks around the coils and plugs! I have been using Q-Tips to absorb this oil and get the crumbled bits of plastic out. I also found that the mechanic used electrical tape to sloppily fasten the wires/clip to the ignition coil, the one that is closest to the oil reservoir cap. I am assuming that these are the wires that he is telling me need replacing.

I clearly have a number of issues going on here. I have been tirelessly reading Matthew's Volvo Site blogs and forums to determine what to do to remedy this issue. UGH! Any and all correspondence is appreciated!!

With sincere thanks,
-Aaron

2001 Volvo S40 163,000 mi
1991 Volvo 240 265,000 mi
1986 Volvo 240 DL 195,000 mi

[JDS60R]

Volvo sells the connectors and female clips. A qualified auto electrician would simply install the new clips ,females and wires and then solder them into place on the harness. To speed things up a salvage yard can sell you the harness cut or disconnected wherever you chose.