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'88 240 ICU plug

Help, Advice, Owners' Discussion and DIY Tutorials on all Volvo's "mid era" rear wheel drive Volvos.

1975 - 1993 240
1983 - 1992 740
1982 - 1991 760
1986 - 1991 780
1990 - 1998 940
1990 - 1998 960
1997 - 1998 V90/S90

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DarDaq
Posts: 1
Joined: 5 September 2011
Year and Model: '88 240 Wagon
Location: NYC

'88 240 ICU plug

Post by DarDaq »

I have an '88 wagon with intermittent stalling issues. A couple years ago, I narrowed the issue down to a worn hall effect wire. The trouble is that the affected part of the wire is very close (as in millimeters) to where it joins the plug for the ignition control unit near the passenger fender well. I was able to very carefully cut the hall effect wire and solder in a new section of wire (it was pretty tight quarters, not sure I'd be able to re-do it), and this seemed to solve the problem for a year or so, but now the stalling is back. I'm always able to get the car to start right back up by jumping out and wiggling the plug/wire, but the stalling is becoming more frequent lately and having to jump out to pop the hood in rush hour traffic isn't ideal. I had a couple of ideas, but could use some feedback:

1) I'm curious if I could pull the hall wire out of the ICU plug and try to reattach it somehow with a better section of wire. Does anyone have any experience with this? is it possible?

or

2) I also thought I might be able to find someone with a wiring harness that would be willing to cut their ICU plug off the harness and sell to me so I can solder it into my harness. Anyone out there have an old wiring harness or know where to find one?


Anyone have any other suggestions?

jimmy57
Posts: 6694
Joined: 12 November 2010
Year and Model: 2004 V70R GT, et al
Location: Ponder Texas
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Post by jimmy57 »

An issue that effects that Chrysler built ignition is the pins getting loose from the circuit board due to cracked solder joint.
Take the ICU out and take it apart and clean off the gel stuff and inspect. You will have to re-solder those pins where they attach to the board. If you want to confirm this is it you can usually take a probe of some sort and see if any of the pins wiggle.

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