Ignition System Replacement (GROUP 37, NO. 11)

IGNITION SYSTEM REPLACEMENT

TECHNICAL SERVICE BULLETIN

IGNITION SYSTEM HARNESS, REPLACEMENT

Models: Volvo 1980-on 240

Bulletin No.: 11

Group: 37

Date: November 1992

SERVICE INFORMATION

This bulletin replaces Service Bulletin Group 37, No. 11 dated July 1988.

NEW CABLE HARNESS - CHRYSLER IGNITION SYSTEM

1988 M/Y 240 models are equipped with a Chrysler ignition system incorporating a new type of control unit and cable harness P/N 3515885-6.

If it is necessary to replace the cable harness on certain older vehicles, the new cable harness should be used. Note, however, the different part numbers.

Model Year	Part Number
1980, 1981, 1982, 1983	Use P/N 3515722-1
1984	Two different cable harnesses are available. For cable harness P/N 1346259-3 (ignition coil located on left side.), use 3515723-9. For cable harness P/N 1347847-4 (ignition coil located on right side), use 3515885-6 (1)
1985-on	Use P/N 3515885-6 (1)
(1) A new twin-pole cable harness connector was introduced on 1987 models. When cable harness P/N 3515885-6 is installed on 1985 and 1986 models (and certain 1984 models, see chart), the twin-pole connector on the new cable harness should be cut off and removed since there is no appropriate connection to the engine wiring harness.

When replacing a cable harness, note that three pin sleeves must be removed from the control unit connector.

SERVICE PROCEDURE

1. Disconnect battery ground cable.
2. Cut off twin-pole connector. (This applies only to 1986, 1985 and 1984 models which require replacement cable harness P/N 3515885-6).
3. Cut off wires to the twin-pole connector (near the ignition coil connector). Cut the wires at different lengths as shown in Fig 1 . Insulate each wire separately. Fold back wires and wrap tape around cover.
   Fig 1: Cutting Off Twin-Pole Connector

   
   NOTE: It is essential that the wires do not touch each other or any metal parts as this can cause a short circuit.
4. Remove connector pin sleeves 3, 5 and 9 from control unit connector. Use a pair of flat-nosed pliers to remove connector sleeves. To prevent damage to connector pins, place side of pliers over sleeve groove and carefully twist sleeve to remove it. See Fig 2 .
   Fig 2: Removing Connector Pin Sleeves

   
   CAUTION: Control unit pins must not be bent. Damage to pins will require control unit replacement.
5. Check connector rubber seal. Make sure that the rubber seal is correctly fitted before connecting the connector to the control unit. See Fig 3 .