2 4 0 T U R B O . C O M
D A V E ' S   V O L V O   P A G E
Volvo Harness Parts
Connectors, Terminals, Etc.


  UPDATED: October 16, 2018        CONTACT      SHIPPING    VIEW CART
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C l i c k   a   L i n k   B e l o w
Sealed or Waterproof FUSE Holders VOLVO BOSCH EFI PLUGS 2-Pole, 3-Pole, 6-Pole, 7-Pole
VOLVO 1-Pole, 2-Pole, 3-Pole, 4-Pole and 8-Pole Sealed Harness Plugs Wire Pigtails for VOLVO Harness Plugs
Volvo 2-Speed Cooling Fan Relay Connectors
.187 inch (4.7 mm) Small Terminals
5-Pole Standard RELAY Plugs
.250 inch (6.3 mm) Terminals for Relay Plugs
6-Pole Fuel Pump Relay Plug
VOLVO Headlight STEP RELAY Plug Housings
Headlight Harness Plugs .312 inch .312 inch Terminals for Headlight Plugs
Large Terminals .375 inch (9.5 mm) OVERCRIMPS for using LARGE Wire with Not-So-Large Terminals
Bullet Plugs and Terminals (non-sealed 3.5 mm VOLVO under-dash type) BLACK VINYL HARNESS TUBING Sizes 1/8 to 1 inch Diameter
Terminal Blocks

Helpful Instructions: CRIMPING EFI TERMINALS
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SEALED FUSE HOLDER  --  Assembled or Unassembled Kit
Sealed Fuse Holder Kit<<< This waterproof fuse holder uses a standard blade fuse (ATO/ATC type),
same as original on a 240 fender fuse holder pictured at right >>>).
Volvo 240 Fuse Holder
  
If your 240 has ever had a dirty or corroded LH Injection fuse then a sealed fuse holder like this will keep that from happening. 

Available in three kit types:
Kit #1: Fully assembled with 12 gauge wire (as shown above), 36 inch loop wire, with 25A fuse

$12.00 plus shipping.  IN STOCK

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Kit #2: UNASSEMBLED kit that you may assemble and install on your car (25A fuse included).  
This unassembled kit includes the fuse, waterproof housing, cap, and crimp terminal inserts. Use your own 12 or 14 gauge wire (Volvo used 14 gauge originally).  Assembly is easier than you think.

$8.00 plus shipping.  IN STOCK

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Kit #3: Fully assembled fuse holder installed by us on a new harness (with new harness purchase only) (25A fuse included). 

$8.00 plus harness purchase. 
IN STOCK

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SEALED FUSE HOLDER  --  Big 10 Gauge Wire
Sealed Fuse Holder KitThis sealed, water-resistant, in-line fuse holder features big 10 gauge wire leads (12 inch wire loop). It uses a standard blade fuse (ATO/ATC type).   If youre installing an electric primary cooling fan or any other high current device and need a large wire fuse holder, then this will do well.  40A fuse included.

$5.00 each plus shipping.  IN STOCK

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Bosch Style Fuel Injection (EFI) Connector Plugs, Parts

2-Pole Female EFI Plug Housings
Female EFI Terminal Inserts
2-Pole MALE EFI Plug Housings MALE EFI Terminal Inserts
3-Pole Female EFI Plug Housings
Blue EFI Rear Plug Seals
6-Pole Female EFI Plug Housings 7-Pole Female EFI Plug Housings
Instructions: CRIMPING EFI TERMINALS

Bosch style Female EFI 2-Pole Plug Housing.
Fuel Injection 2-Pole Plug Fuel Injection 2-Pole Plug These are used for Fuel Injectors or Sensors (AKA: EV1 housing).
Connector Housing Only. Terminal inserts NOT included
(terminals are available below).
Instructions: CRIMPING EFI TERMINALS
 
$5.00 each plus shipping.  IN STOCK

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EFI Female Crimp Terminal Insert.
EFI Crimp TerminalsEFI Crimp Terminals   For Female EFI Plug Housings.
These terminals fit the above Female EFI plug housing and are typically crimped onto 14-18 gauge wire.  These are also the correct fitting terminals for many other Volvo engine connector plugs, such as the MAF (Mass Air Meter), Throttle Position Sensor and many engine sensors.
Instructions: CRIMPING EFI TERMINALS
   
$0.45 each plus shipping.  IN STOCK

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Fuel Injection Male 2-Pole Plug Bosch style MALE 2-pole EFI Type Plug Housing. 
(AKA: EV1 housing)
Terminal Inserts available below.
Instructions: CRIMPING EFI TERMINALS
$5.00 each plus shipping.  IN STOCK

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EFI Male Crimp Terminal Insert.
For Male EFI Plug Housings.

These terminals fit the above Male EFI connector plug housing and are typically crimped onto 14-18 gauge wire. 
Instructions: CRIMPING EFI TERMINALS




    
$0.45 each plus shipping.  IN STOCK

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Bosch style Female 3-pole EFI type Sensor Connector Plug Housing.  Housing only.  Fits Volvo TPS, some Idle Valves, Crank Position Sensor.
Crimp Terminal Insert NOT included (available below).
Instructions: CRIMPING EFI TERMINALS




   
$5.00 each plus shipping.  IN STOCK

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EFI Crimp TerminalsEFI Crimp TerminalsEFI Female Crimp Terminal Insert.
For all Female EFI Plug Housings on this page.

These terminals fit the above Female EFI plug housing and are typically crimped onto 14-18 gauge wire.  These are also the correct fitting terminals for many other Volvo engine connector plugs, such as the MAF (Mass Air Meter), Throttle Position Sensor and many engine sensors.


Instructions: CRIMPING EFI TERMINALS

    
$0.45 each plus shipping.  IN STOCK

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Bosch style Female 6-pole EFI type MAF Sensor Connector Plug Housing.  Fits Volvo LH 2.0, 2.2 and 2.4 Mass Air Sensor.
Crimp Terminal Inserts are NOT included (available separately above).
This one is available with a rubber boot or without.
Optional silicone seals are available BELOW to use instead of a boot.
Instructions: CRIMPING EFI TERMINALS


6-pole Connector $12.00 each plus shipping.  IN STOCK
6-pole Connector with Rubber Boot $18.00 plus shipping.  IN STOCK

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  Bosch style Female 7-pole EFI type Sensor Connector Plug Housing.  Fits Volvo LH 2.4 Ignition Power Stage.
Crimp Terminal Inserts are NOT included (available separately above).
Optional silicone seals are available BELOW to use instead of a boot.
Instructions: CRIMPING EFI TERMINALS


7-pole Connector $10.00 each plus shipping.  IN STOCK

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Silicone Seals for above EFI Connector Housings.
These seals fit into the back of these EFI plug housings and will seal the wire going into the back side from moisture.  Using these seals is a suitable option if you will not be using a rubber boot.  They are generally not needed if you are using a rubber boot, but still may be used for extra sealing if desired.  Two are needed for a 2-pole male or female plug housing.
Instructions: CRIMPING EFI TERMINALS




  
$0.15 each plus shipping.  IN STOCK

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VOLVO Sealed Connector Plugs and
Bullet Terminal Inserts for Volvo Engine Harnesses

8-Pole Female Volvo Plugs
8-Pole MALE Volvo Plugs
2-Pole Female Volvo Plugs
2-Pole MALE Volvo Plugs
3-Pole Female Volvo Plugs
3-Pole MALE Volvo Plugs
4-Pole Female Volvo Plugs
4-Pole MALE Volvo Plugs
Female Bullet Pigtails
MALE Bullet Pigtails
1-Pole Female Bullet Plug with Pigtail
2-Speed Cooling Fan Relay Connectors

A helpful guide for 240 firewall harness loom repairs may be found at the below link: 

http://www.davebarton.com/pdf/harness_firewall_loom_repair_240t.pdf

OPENING VOLVO SEALED PLUG HOUSINGS
Use a small (micro) screwdriver or a pick to pry the back door open.  It will not require much effort.  When closing, it will snap into place.


FEMALE 8-Pole Plug

Genuine Volvo FEMALE 8-pole sealed bullet connector housing.
Commonly found on Volvo engine harnesses. Many older original plugs were gray. This is now black. These are the later type and are slightly different from the early type found on late-1970s or early 1980s Volvos. 

This is the housing only. These use the below sealed female bullet terminal inserts for a weatherproof connection: CLICK HERE
$6.00 each plus shipping.  IN STOCK

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Click photo for larger image
MALE 8-Pole Plug

Genuine Volvo MALE 8-pole sealed bullet connector housing.
For common Volvo engine harnesses using an 8-pole firewall or fender plug.  Black plastic. These are the later type and are slightly different from the early type found on late-1970s or early 1980s Volvos. 

This is the housing only. These use the below sealed male bullet terminal inserts for a weatherproof connection: CLICK HERE
$6.00 each plus shipping.  IN STOCK

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FEMALE 2-Pole Plug

Genuine Volvo FEMALE 2-pole sealed bullet connector housing.
For common Volvo engine harnesses using a 2-pole female plug for some engine sensors, rear differential speed sensor or sometimes a fender or firewall plug.  These use the below female 3.5 mm sealed bullet terminal inserts for a weatherproof connection. 

This item is the housing only. The female bullet terminal pigtails are offered separately below: CLICK HERE
Thais is an ORIGINAL VOLVO CONNECTOR, marked STD 7614.31 (That's not a part number. the same number appears on several different Volvo harness connectors).

$6.00 each plus shipping.  IN STOCK

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MALE 2-Pole Plug

Genuine Volvo MALE 2-pole sealed bullet connector housing.
For common Volvo engine harnesses.  These use the below male 3.5 mm sealed bullet terminal inserts for a weatherproof connection.  This is the housing only. The male bullet terminal insert pigtails are sold separately below: CLICK HERE
$4.00 each plus shipping.  IN STOCK

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Genuine Volvo FEMALE 3-pole sealed bullet connector housing.
For common Volvo engine harnesses using a 3-pole plug for a fender or firewall plug or other device.  These use the below female 3.5 mm bullet terminal inserts for a weatherproof connection.
These have been out of production from Volvo for a few years, but they are still available for a limited time.
This is the housing only. The female bullet terminal insert pigtails are sold separately below: CLICK HERE.
$6.00 each plus shipping.  IN STOCK

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Genuine Volvo MALE 3-pole sealed bullet connector housing for common Volvo engine harnesses using a 3-pole plug for a fender or firewall plug or other device.  These use the below male 3.5 mm bullet terminal inserts for a weatherproof connection.

These have been out of production from Volvo for a few years, but they are still available for a limited time.

This is the housing only. The male bullet terminal insert pigtails are sold separately below: CLICK HERE.
$6.00 each plus shipping.  IN STOCK

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FEMALE

Genuine Volvo FEMALE 4-pole sealed bullet connector housing
This is the housing only.
The female bullet terminal insert pigtails are sold separately below: CLICK HERE.
This is an ORIGINAL VOLVO PART marked STD 7614.31 (That's not a part number. It appears on several different Volvo harness connectors).

COMMON USES:
740/940 models: Radio Noise Suppression Relay Plug.
240 models: Cooling Fan Relay Plug.
 


These have been out of production from Volvo for a few years, but they are still available for a limited time.

$6.00 each plus shipping.  IN STOCK

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MALE

Genuine Volvo MALE 4-pole sealed bullet connector housing for some Volvo engine harnesses and connector locations. This is the MALE opposite of the female 4-pole plug directly above. 

These have been out of production from Volvo for a few years, but they are still available for a limited time.
 

This is the housing only.
The female bullet terminal insert pigtails are sold separately below: CLICK HERE.

$6.00 each plus shipping.  IN STOCK

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FEMALE

FEMALE 3.5 mm WIRE PIGTAILS: Female bullet wire pigtail inserts for all above Volvo sealed connector plug housings.  Each pigtail comes with approximately 24 inches (60 cm) of wire.  Several wire colors are available.  (These are inserts with wire only. Pictured connector plug housing below NOT included)

<<<
This is the M46/M47 transmission REVERSE LIGHT switch. 
If you need proper fitting connectors to fit this switch, then these pigtails will be the ticket.

WIRE SIZES: Most colors are standard 1.0 mm² (metric size), which is comparable to approximately AWG 17-18 (18 gauge). If you need a larger wire, the Fat wire colors below may help.
Fat Yellow/Blue: 2.0 mm² (metric)
, which is comparable to approximately AWG 14 (14 gauge). 
Fat Red Black or Blue: A fatter red, black or blue wire is also available in 2.5 mm² (metric), which is comparable to approximately AWG 13 (13 gauge). That is the fattest wire available for these pigtails.

If you need a lot of one color you might email first. I don't always keep a large quantity of each color in stock.  Occasional I run out and it can take a few weeks to get more if I do.

Price:  $4.80 each for standard 1.0 mm² wire.
Price:  $5.50 each for Fat Yellow/Blue 2.0 mm² wire or Fat Red, Black or Blue 2.5 mm² wire.
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MALE

MALE 3.5 mm WIRE PIGTAILS: Male bullet terminal pigtail inserts for all above Volvo sealed connector plug housings.  Each pigtail comes with approximately 24 inches (60 cm) of wire. Several wire colors are available.  (These are inserts with wire only. Pictured connector plug housing NOT included)

WIRE SIZES: Most colors are standard 1.0 mm² (metric size), which is comparable to approximately AWG 17-18 (18 gauge).
If you need a larger wire, you may choose the Fat Yellow/Blue, which has a 50% fatter wire size: 1.5 mm² (metric size), which is comparable to approximately AWG 14-15 (14 gauge). 

If you need a lot of one color you might email first. I don't always keep a large quantity of each color in stock.  Occasional I run out and it can take a few weeks to get more.
Price:  $4.80 each for standard 1.0 mm² wire.
Price:  $5.50 each for Fat Yellow/Blue 2.0 mm² wire or Fat Red, Black or Blue 2.5 mm² wire.
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FEMALE

Comes assembled as pictured.
Special FEMALE 1-POLE Sealed Bullet Plug Housing with terminal insert and wire pigtail:
Female bullet terminal pigtail with pictured Volvo 1-pole plug housing. This comes FULLY ASSEMBLED. 
Housing is an ORIGINAL VOLVO PART marked STD 7614.31 (That's not a part number. It appears on several different Volvo harness connectors).

<<< If you're looking for the correct sealed connectors for this Volvo (Bosch) fuel pump, or for the Oil Pressure Sender on B230F/FT engines, then these are the correct ones.

WIRE SIZES: Most colors are standard 1.0 mm² (metric size), which is comparable to approximately AWG 17-18 (18 gauge). If you need a larger wire, the Fat wire colors below may help.
Fat Yellow/Blue: 2.0 mm² (metric)
, which is comparable to approximately AWG 14 (14 gauge). 
Fat Red Black or Blue: A fatter red, black or blue wire is also available in 2.5 mm² (metric), which is comparable to approximately AWG 13 (13 gauge). That is the fattest wire available for these pigtails.
Price:  $4.80 each for standard 1.0 mm² wire.
Price:  $5.50 each for Fat Yellow/Blue 2.0 mm² wire, or Fat Red, Black or Blue 2.5 mm² wire. 
IN STOCK


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Volvo Cooling Fan Relay Connectors.  These are the correct Volvo sealed connectors used in the Volvo 2-Speed Cooling Fan Relay found in 1990s 850 and 900 series Volvos. These SEALED connectors use an internal o-ring in the front and a rear seal that is inserted during assembly.  So if you're making repairs or if you're using a Volvo 2-speed relay on another project, I offer the correct matching connectors below. These are the same connectors as originally used by Volvo.

2-Pole Female Connector for speed #1 and #2 power output. It uses special 9.5 mm large terminals.  These special crimp terminals are designed for up to 10 gauge cable.
Terminal amp rating: 40A using 10 or 12 gauge cable.

Cable Seals: For a sealed connector, you should use silicone seals in the connector. BROWN seals or GRAY seals are available.  The seal may be crimped to the terminal at the insulation support tangs.

Rear Cover: The rear cover snaps into place to ensure the connector stays secure (for 2-pole housing only).

<<< Optional GRAY Seal. This seal was not used by Volvo, but it offers a lower price than the original brown seal. It is slightly larger in diameter and fits a little tighter into the back of the connector.
1-Pole Female Connector for primary voltage power input. It also uses the same special 9.5 mm large terminals.  These special crimp terminals are designed for up to 10 gauge cable.
Terminal amp rating: 40A using 10 or 12 gauge cable.

This FEMALE connector is also used in other locations under the hood of 850 and 960 models (main engine harness power connector), where it mates to the same style MALE connector shown below.

Cable Seal: For a sealed connector, you should use a silicone seal in the connector. BROWN seals or GRAY seals are available.  The seal may be crimped to the terminal at the insulation support tangs.

<<< Optional GRAY Seal. This seal was not used by Volvo, but it offers a lower price than the original brown seal. It is slightly larger in diameter and fits a little tighter into the back of the connector.

1-Pole MALE Connector. This connector is not used on a fan relay, but it's used in other locations under the hood of 850 and 960 models (main engine harness power connector), where it mates to the FEMALE connector shown above for main power to the engine harness. The special crimp terminals are designed for up to 10 gauge cable.  Terminal amp rating: 40A using 10 or 12 gauge cable.

Cable Seal: For a sealed connector, you should use a silicone seal in the connector. The shown BROWN seals or GRAY seals are available.  The seal may be crimped to the terminal at the insulation support tangs.

<<< Optional GRAY Seal. This seal was not used by Volvo, but it offers a lower price than the original brown seal. It is slightly larger in diameter and fits a little tighter into the back of the connector.
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2-Pole Gray Female Connector Housing    IN STOCK

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Rear Cover for 2-Pole Connector Housing    IN STOCK

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1-Pole Black Female Connector Housing    IN STOCK

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Female 9.5 mm Special Crimp Terminal (10 gauge wire)    IN STOCK

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1-Pole Gray MALE Connector Housing    IN STOCK
Not used with Fan Relay

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MALE 9.5 mm Special Crimp Terminal (10 gauge wire)    IN STOCK
Not used with Fan Relay

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Brown Cable Seal    IN STOCK

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Gray Cable Seal    IN STOCK

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Genuine Volvo FEMALE 2-pole sealed bullet connector housing.
For this fan relay this connector serves the MIDDLE temperature sensor circuit.  This connector housing uses the below female 3.5 mm sealed bullet pigtail inserts for a weatherproof connection. 

This is an ORIGINAL VOLVO PART, marked STD 7614.31 (That's not a part number. It appears on several different Volvo harness connectors).
2-Pole Gray Female Sealed Bullet Connector Housing.     IN STOCK

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FEMALE 3.5 mm WIRE PIGTAILS: Female bullet wire pigtail inserts for above Volvo sealed connector plug housing.  Each pigtail comes with approximately 24 inches (60 cm) of wire.
Price:  $4.80 each for standard 1.0 mm² wire.
Price:  $5.50 each for Fat Yellow/Blue 2.0 mm² wire or Fat Red or Black or Blue 2.5 mm² wire.
IN STOCK

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Standard Relay Plugs and Terminals

5-Pole Relay Plug
5-Pole Interlocking Relay Plugs
6-Pole Fuel Relay Plug
240 Headlight Step Relay Plugs
.250 inch (6.3 mm) Plug Terminals


5-Pole Female RELAY PLUG
Fits all standard 4 or 5-pole mini relays. Uses .250 inch (6.3 mm) female locking terminals (offered below).


Click here for tips on removing wire connector inserts from these sockets.

IN STOCK
 $2.00 each, or buy 2 or more for $1.50 each.


5-pole Relay Plug ($2.00 for 1):

5-pole Relay Plug (2 or more for $1.50 ea.):

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5-Pole Interlocking RELAY PLUG SOCKET
Fits all standard 4 or 5-pole mini relays. Uses .250 inch (6.3 mm) female locking terminals (offered below).
Click here for tips on removing wire connector inserts from these sockets.

IN STOCK
$2.50 ea.
or buy 2 or more for $2.00 ea.


5-pole Interlocking Relay Plug ($2.50 for 1):

5-pole Interlocking Relay Plug (2 or more for $2.00 ea.):

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6-Pole Female RELAY PLUG CONNECTOR HOUSING

Fits all Volvo 6-pole fuel pump relays using this plug. Uses .250 inch (6.3 mm) female locking terminals (offered below).

Correct fuel pump relay plug replacement for all 240 models with fuel injection (all mechanical or electronic fuel injection).

Click here for tips on removing wire terminal inserts from these sockets.
IN STOCK
 $3.00 each.
<<< A customer found this damage when inspecting his 240 fuel pump relay.  This is a common occurrence. It does not happen because of too much current at that connector.  It happens after years of corrosion gets introduced and slowly builds in high current connections. That corrosion causes there to be more resistance, which then causes more heat to build. Ultimately you have a melted connector like this, which fails. 
A good cure for this is found here: http://www.240turbo.com/volvorelays.html#fuelpumprelay

IN STOCK
 $3.00 each.


6-pole Female RELAY PLUG  $3.00:


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 Genuine Volvo 240 HEADLIGHT STEP RELAY PLUGS
<<< For all Volvo headlight step relays.
Genuine Volvo replacements in case yours are melted, damaged, etc.
Uses .250 inch (6.3 mm) female locking terminals (offered below).

Click here for tips on removing wire terminal inserts from these sockets.
Two types: 
3-pole relay plug: $3.00 each In Stock
5-pole relay plug: $3.00 each In Stock

3-Pole Relay Plug ORDER HERE:

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5-Pole Relay Plug ORDER HERE:

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 .250 inch (6.3 mm) FEMALE terminals.  For all above relay plug housings.
AMP RATING:  28 amps using 4 mm² to 6 mm²  (10-12 AWG) wire.
Two wire sizes available:
  SMALL: 14-18 gauge wire recommended.   $0.40 each
  LARGE: 10-12 gauge wire recommended.   $0.50 each
NOTE: The LARGE terminals will normally accept a maximum of 10 gauge wire, however it is possible to use it with larger 8 gauge cable. 
This is done using a large overcrimp. See pics below.
Overcrimps can be found further below, or CLICK HERE
 
IN STOCK

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Quantity discounts available on orders of 50 or more of either size: $0.25 each
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.250 inch (6.3 mm) Plugs and Terminals


1-Pole .187 inch Female Plug BLACK
1-Pole .250 inch Female Plug WHITE
1-Pole .250 inch Female Plug BLACK
.187 inch Female Crimp Terminals
.250 inch Female Crimp Terminals
Special .250 inch "Piggybacks"
.250 inch MALE Crimp Terminals 1-Pole .250 inch MALE Plug WHITE
1-Pole .250 inch MALE Plug BLACK 2-Pole .250 inch Female Plug
2-Pole .250 inch MALE Plug 4-Pole .250 inch Female Plug
4-Pole .250 inch MALE Plug 6-Pole .250 inch Female Plug
6-Pole .250 inch MALE Plug 8-Pole .250 inch Female Plug
8-Pole .250 inch MALE Plug


Click photo for larger image
1-Pole Female Insulator (BLACK) for all .187 inch (4.7 mm) female terminals.
As shown on left, insulator only.
Fits either small or large wire terminal.  $0.35 ea.
Quantity Discount:  20% discount for 10 or more:   $0.28 ea.
Quantity Discount:  30% discount for 20 or more:   $0.24 ea.
Discounts are calculated automatically when you order.
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    ,30e
ORDER HERE: (1-Pole Insulator BLACK for .187 inch FEMALE Terminals) Order Quantity:


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1-Pole Female Insulator (white) for all .250 inch (6.3 mm) female terminals.
As shown on left, insulator only.
Fits either small or large wire terminal.  $0.30 ea.e
Quantity Discount:  20% discount for 10 or more:   $0.24 ea.
Quantity Discount:  30% discount for 20 or more:   $0.21 ea.
Discounts are calulated automatically when you order.


   

ORDER HERE: (1-Pole Insulator WHITE for all .250 inch FEMALE Terminals) Order Quantity:


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1-Pole Female Insulator (BLACK) for all .250 inch (6.3 mm) female terminals.
As shown on left, insulator only.
Fits either small or large wire terminal.  $0.60 ea.
Quantity Discount:  20% discount for 10 or more:   $0.48 ea.
Quantity Discount:  30% discount for 20 or more:   $0.42 ea.
Discounts are calculated automatically when you order.
bos0


    ,30e
ORDER HERE: (1-Pole Insulator BLACK for all .250 inch FEMALE Terminals) Order Quantity:


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  .187 inch (4.7 mm) female terminals.
Fits 16-20 gauge wire.  $0.35 ea.
Quantity Discount:  20% discount for 10 or more:   $0.28 ea.
Quantity Discount:  30% discount for 20 or more:   $0.24 ea.
Discounts are calculated automatically when you order.
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    ,30e
ORDER HERE: ( .187 inch FEMALE Terminals) Order Quantity:


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 .250 inch (6.3 mm) FEMALE terminals.  For all above relay plug housings.
AMP RATING:  28 amps using 4 mm² to 6 mm²  (10-12 AWG) wire.
Two wire sizes available:
  SMALL: 14-18 gauge wire recommended.   $0.40 each
  LARGE: 10-12 gauge wire recommended.   $0.50 each

NOTE: The LARGE terminals will normally accept a maximum of 10 gauge wire, however it is possible to use it with larger 8 gauge cable. 
This is done using a large overcrimp. See pics below.
Overcrimps can be found further below, or CLICK HERE
 
IN STOCK

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Quantity discounts available on orders of 50 or more of either size: $0.25 each
Order Quantity: Select Size:

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Click photo for larger image
.250 inch (6.3 mm) Special Female Terminal with Male "Piggyback"
Small: for 18-22 gauge wire.   $0.30 ea.
Large: for 10-16 gauge wire.   $0.40 ea.
Hard to find. Commonly used on 240 fuse panel    (p h o t o   t o   r i g h t  > > >)






IN STOCK

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.250 inch (6.3 mm) male terminal.
Available in TWO wire sizes. 
SMALL: For 14-18 gauge wire.   $0.40 ea.
LARGE: For 10-14 gauge wire.   $0.50 ea.
AMP RATING:  28 amps using 4 mm² to 6 mm²  (10-12 AWG) wire.

   




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1-Pole Male Insulator (white) for above .250 inch (6.3 mm) male terminal.
As shown on left, INSULATOR ONLY.  
$0.40 ea.




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1-Pole Male Insulator (BLACK) for above .250 inch (6.3 mm) male terminal.
As shown on left, INSULATOR ONLY.  
$0.40 ea.



    


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2-Pole FEMALE Plug Housing for above .250 inch (6.3 mm) female terminal.
Plug housing only.  
$0.80 ea.




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2-Pole MALE Plug Housing for above .250 inch (6.3 mm) male terminal.
Plug housing only.
$0.80 ea.




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4-Pole FEMALE Plug Housing for above .250 inch (6.3 mm) female terminal.
Plug housing only.
$1.40 ea.   




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4-Pole MALE Plug Housing for above .250 inch (6.3 mm) male terminal.
Plug housing only. 
$1.40 ea.   




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6-Pole FEMALE Plug Housing for above .250 inch (6.3 mm) female terminal.
Plug housing only. 
$3.00 ea.   




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6-Pole MALE Plug Housing for above .250 inch (6.3 mm) male terminal.
Plug housing only. 
$3.00 ea.   




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8-Pole FEMALE Plug Housing for above .250 inch (6.3 mm) female terminal.
Plug housing only.  
$3.00 ea.    




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8-Pole MALE Plug Housing for above .250 inch (6.3 mm) male terminal.
Plug housing only.  
$3.00 ea. 




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Headlight Plugs and Terminals

3-Pole "Flag" Headlight Plug
.312 inch "Flag" Terminal
3-Pole Straight Plug
.312 inch Straight Terminal (Small)
.312 inch Straight Terminal (Large)


Click photo for larger image


Headlight Plug Housing (3-poles).
Fits Standard or H1 or H4 type (also 9003).
Uses .312 inch (7.9 mm) FLAG terminals (shown below).

This is a standard (flag) plug for all H1 and H4 headlight bulbs. It uses the .312 inch (7.9 mm) 90 degree (flag) terminal shown below.  Use this plug to repair or build your own new headlight harness.

Detailed information and relay diagrams for building a great headlight harness: http://www.240turbo.com/volvo240mods.html#headlightrelayharness



$1.50 each,    IN STOCK 


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.312 inch (7.9 mm) Female Locking Flag Terminal for above Headlight Plug.
90 degree (flag) type terminal. Hard to find terminal for wire size 12-16 gauge. 12 gauge will fit if you're careful. It takes a little finesse. No flag terminal of this type will hold larger wire than this one.  Has correct tab for locking into place in a flag headlight plug (above).

This terminal will not accept an overcrimp. 
If you want to use big 10 gauge wire for your headlights, I recommend changing to the straight type plug below.



$0.45 each,   IN STOCK 


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Headlight Plug Housing (3-poles).
Fits Standard or H1 or H4 type (also 9003).
Uses .312" STRAIGHT female terminals (below).

This is a standard plug for all standard headlights or H1 / H4 headlight bulbs. It uses the .312 inch (7.9 mm) straight terminal shown below.  Use this plug to repair or build your own new headlight harness.

If you want to use big 10 gauge wire for your headlight relay harness, I recommend changing to this straight type plug. Scroll down for more.

Detailed information and relay diagrams for building a great headlight harness: http://www.240turbo.com/volvo240mods.html#headlightrelayharness



PRICE: $1.75 each.   IN STOCK 


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.312" (7.9 mm) Female Locking Terminal for above STRAIGHT Headlight Plug.
Fits 12-16 AWG wire.

Straight type, hard to find terminal for large wire size 12-16 gauge.  Fits the black headlight plug housing above. Has correct tab for locking into place.
AMP RATING:  28 amps using 4 mm² to 6 mm²  (10-12 AWG) wire.

<<< Do you want to use this terminal with big 10 gauge wire to make an ultimate headlight harness?  Use a small OVERCRIMP (see photo). The OVERCRIMPS are available a bit further below or CLICK HERE.





.312 Female Straight Terminal 12-16 AWG
PRICE:  $0.65 each.   IN STOCK

 

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.312" (7.9 mm) Female Locking Terminal for above STRAIGHT Headlight Plug.
Largest Size: Fits 10-12 AWG wire.
AMP RATING:  28 amps using 4 mm² to 6 mm²  (10-12 AWG) wire.
These terminal inserts were VERY hard to find.  Fits the black straight headlight plug housing shown (same as above). Fits large wire sizes: 10 gauge wire shown in photo.  There is no other headlight terminal that will hold 10 gauge wire. 
Fits the above straight headlight plug, except for ONE PROBLEM:
These terminals lack the locking tab, which "clicks" and locks the terminal into the housing.  Without this locking tab, the terminal could be pulled out the back (which would not happen after being plugged in of course).  However, if this bothers you, a solution is to drop a blob of epoxy into the back of the housing as shown in the photo.

Detailed information and relay diagrams for building a great headlight harness: http://www.240turbo.com/volvo240mods.html#headlightrelayharness



.312 Female Straight Terminal for large 10 Gauge wire
PRICE:  $0.75 each.   IN STOCK

 


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.375 inch (9.5 mm) Terminals

3-Pole "Flag" Headlight Plug
.312 inch "Flag" Terminal
3-Pole Straight Plug
.312 inch Straight Terminal (Small)
.312 inch Straight Terminal (Large)


Click photo for larger image

375" (9.5 mm) FEMALE Crimp Terminal
Hard to find large terminals for large wire sizes.
<<< TWO Wire Sizes: 10-12 gauge small (terminal on left) or 8-10 gauge large (terminal on right).
AMP RATING:  50 amps using 10 mm² (7-8 AWG) wire.
<<< if needed, you may even use this terminal with up to 6 gauge wire?  Use a large OVERCRIMP to accomplish this.  Overcrimps are available below or CLICK HERE.
<<< This is the correct size terminal to fit the large male spade on a 240 wire junction box (<<< shown on left).  This Volvo junction box originally used the 10-12 gauge wire terminal (size: small).

ORDER HERE:
PRICE: $0.75 each, either size.  IN STOCK
 

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.375" (9.5 mm) MALE Crimp Terminal
Hard to find large male terminal for large wire sizes: Fits large 8-12 gauge wire.  Using a .375 inch male and female for high-power connections is a much better choice than more common .250 inch (6.3 mm) terminals.  If you're skeptical about this, have a look at the below comparison photo.  High-power connections using a heavy amp load, such as a BIG primary cooling fan, will eventually overheat a small connection.  That will cause a future failure.  Insulating these can be done with some simple heat-shrink tubing.
AMP RATING:  50 amps using 10 mm² (7-8 AWG) wire.

 
If needed, you may even use this terminal with up to 6 gauge wire?  Use a large OVERCRIMP to accomplish this.  Overcrimps are available below or CLICK HERE.

<<< Comparison photo of .375" terminals to ordinary .250" terminals.
These large terminals provide substantially more conductor surface area for a high-load connection.

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PRICE: $0.75 each,   IN STOCK 


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PROPER CRIMPING tools are important. 
<<< Try not to use a cheap crimper or the wrong type for the terminal you're using.  To start with, buy yourself a basic crimper at least as good as this one pictured. 
 For those of you who are curious about what crimper I use, this one at left works for 90% of my crimps for non-insulated and many insulated terminals.  Thomas & Betts model WT 112M. It runs about $45, but there are less expensive knock-offs out there. I've probably had this one for 25 years.  With some practice, this tool can create nice crimps just like a fancy tool.
<<< For a tool that's a bit more fancy, look for a ratcheting crimper that will do open barrel F type terminals.  You can spend a lot of money on one of these tools, but it you hunt carefully, you can find something like this one, which is only $31 for all that stuff.  The crimp type dies normally used for terminals on this page is the die set in the center.  The other dies might come in handy, so they would be a bonus.  I don't own this tool.  Mine was closer to $100 ten plus years ago. This one is cheap and might be worth the cost, or it might explode. You can never really tell until it's in your hands and you try it out.
HERE: https://www.amazon.com/dp/B01CVH8JNO?psc=1


Here's a good crimping guide for beginners: http://www.xj4ever.com/crimping my style.pdf

Here's a decent video showing close-up crimping action for an open barrel terminal.





Overcrimps for Large Wire



SMALL OVERCRIMP PIC





LARGE OVERCRIMP PIC


OVERCRIMPS for using Oversized Wire on Undersized Terminals
Hard to find open barrell terminal OVERCRIMPS in two sizes: Small and Large. For use when your wire is a bit oversized for the terminal.  In an ideal world, you would simply find a terminal that accepts larger wire. Try that with 8 or 10 GA wire on most available terminals.  Sometimes the fit just isn't good enough.  Adding one of these overcrimps can really be a life saver. 
Overcrimps will not fit FLAG style terminals.
Overcrimp
TWO SIZES:  
<<< SMALL OVERCRIMP
Typically works on terminals that normally allow a MAX of 12 GA wire.  This will allow the use of 10 GA wire instead. 

PRICE: $0.25 ea          IN STOCK

<<< LARGE OVERCRIMP
Typically works on terminals that normally allow a MAX of 8 or 10 GA wire.
This will allow the use of up to 6 to 8 GA wire instead. 

PRICE: $0.50 ea           IN STOCK



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Quantity Discount: 10 or more.   Small: $0.20 each.   Large: $0.40 each.

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Quantity Discount: 50 or more.   Small: $0.15 each.   Large: $0.30 each. 
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OVERCRIMP TECHNICAL SPECS:
Small overcrimp: Brass wall thickness 0.025 inch (0.635 mm).
Length: 0.250 inch (6.35 mm).
Width: 0.220 inch (5.59 mm).
Height: 0.300 inch (7.62 mm). 
Distance between wings: 0.195 inch (4.95 mm).
Large overcrimp:
Brass wall thickness 0.030 inch (0.762 mm).
Length: 0.325 inch (8.25 mm).
Width: 0.345 inch (8.76 mm).
Height: 0.315 inch (8 mm). 
Distance between wings: 0.305 inch (7.75 mm). 

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3.5 mm Bullet Plugs and Terminals (non-sealed).
Typically used for under-dash wiring.

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4-pole Gray MALE Plug Housing
Housing only. Terminals and wire not included. For below 3.5 mm male bullet terminals.
$4.00 each.   IN STOCK

  bos0,85e

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3.5 mm MALE Bullet Terminal. Fits above 4-pole Plug Housing
Terminal only. Plug housing not included.
$0.50 each.   
IN STOCK  b
0.12e
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Insulator for above 3.5 mm MALE Bullet Terminal.
Clear Insulator only. Terminal and wire not included.
$0.30 each.   
IN STOCK  b


os0.12e

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4-pole Blue FEMALE Plug Housing
Housing only. Terminals not included. For below 3.5 mm female bullet terminals.
$4.00 each.  
IN STOCK    bos0,1

5e


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3.5 mm FEMALE Bullet Terminal for above 4-pole Plug Housing
Terminal only.
$0.50 each.  
IN STOCK    bos0.1





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Terminal Blocks


Terminal blocks can come in handy if you want to tidy up your wires. 

These terminal blocks are considered BARRIER type, because there is a defined barrier between each pair of screws.  So this means it's possible to use one block for distribution to multiple cicuits.
I used some of these when I re-wired my dash and installed new AC in my 242 Turbo.  One was used to consolidate the dash grounds from gauges, relays, radio and the AC system into one central location, instead of the way Volvo did it by adding ground points all over in different places. You can see that project here:  http://www.240turbo.com/classicair.html#terminalblocks.

Here you can see THREE different parts.  A few of these parts have been assembled onto this terminal block to shown how they attach.
1.
The terminal block.
2.
A double tab.  This had two male .250 inch (6.3 mm) tabs to easily fit a crimp female push-on  terminal.  This makes things much simpler than crimping on rings or eyelettes. These tabs are set at a 45 degree angle. Rated at 30 amps.
3.
A jumper. This is used to join two or more pairs of screws together.  You would use three of these to make this 4-row block as all one common circuit, such as for an all-in-one ground point.  You would use 7 of them to do the same on an 8-row terminal block. 


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Double Tab, Male.     IN STOCK

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Terminal Block Jumper.     IN STOCK

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High Quality Vinyl Tubing for Wire Harness Applications.
Soft, flexible, high-temperature resistant.
Identical to Volvo OEM vinyl.
Used for vintage electrical harness restorations or custom harness construction.


  
--  MINIMUM Order for below Tubing Please:  $5.00  --
ALL SIZES IN STOCK UNLESS OTHERWISE NOTED
SIZE I/D INTERNAL DIMENSION WALL THICKNESS PRICE PER FOOT
1/8 inch ID: 0.118 inch (3 mm)
Wall thickness: 0.020 inch (0.5 mm)
$0.50 per foot
(weight approx 0.1 oz/ft)
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3/16 inch ID: 0.188 inch (4.8 mm)
Wall thickness: 0.020 inch (0.5 mm)
$0.60 per foot  
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1/4 inch ID: 0.250 inch (6.3 mm)
Wall thickness: 0.020 inch (0.5 mm)
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5/16 inch ID: 0.313 inch (8.0 mm)
Wall thickness: 0.025 inch (0.63 mm)
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3/8 inch ID: 0.375 inch (9.5 mm)
Wall thickness: 0.025 inch (0.63 mm)
$0.90 per foot
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0.32 oz/ft)
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7/16 inch ID: 0.438 inch (11.1 mm)
Wall thickness: 0.025 inch (0.63 mm)
$1.00 per foot
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1/2 inch ID: 0.500 inch (12.7 mm)
Wall thickness: 0.025 inch (0.63 mm)
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9/16 inch ID: 0.563 inch (14.3 mm)
Wall thickness: 0.030 inch (0.76 mm)
$1.40 per foot
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0.63 oz/ft)
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5/8 inch ID: 0.625 inch (15.9 mm)
Wall thickness: 0.030 inch (0.76 mm)
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3/4 inch ID: 0.750 inch (19.0 mm)
Wall thickness: 0.035 inch (0.89 mm)
$1.90 per foot
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1 oz/ft)
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ID: 0.875 inch (22.2 mm) Wall thickness: 0.035 inch (0.89 mm) $2.00 per foot
(weight approx 1.1 oz/ft)
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1 inch ID: 1.00 inch (25.4 mm)
Wall thickness: 0.035 inch (0.89 mm)
CLEARANCE SALE PRICE
$1.00 per foot

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weight approx
1.2 oz/ft)
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