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Plugs, Connectors, Terminals, Etc.  |
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Plugs, Connectors, Terminals, Etc. |
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UPDATED: November 3, 2020 CONTACT SHIPPING VIEW CART |
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| S E A R C H
D A V E ' S V O L V O P A
G E S B E L O W
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| SEALED FUSE HOLDER --
Assembled or Unassembled Kit Available in three kit types:
S H I P P I N G N E E D
S T O B E A D D E
D O N L Y O N E T
I M E P E R O R D E R
Shipping options
are also available at bottom of page: Click Here.
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SEALED FUSE HOLDER -- Big
10 Gauge Wire
S H I P P I N
G N E E D S T O
B E A D D E D O N L
Y O N E T I M E
P E R O R D E R
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| Lambda Oxygen Sensor Repair Plug Parts |
S H I P P I N
G N E E D S T O
B E A D D E D O N L
Y O N E T I M E
P E R O R D E R
Shipping options
are also available at bottom of page: Click Here.
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| Bosch Style Fuel Injection (EFI) Connector Plugs, Parts |
S H I P P I N
G N E E D S T O
B E A D D E D O N L
Y O N E T I M E
P E R O R D E R
Shipping options
are also available at bottom of page: Click Here.
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S H I P P I N G N E E D S T O B E A D D E D O N L Y O N E T I M E P E R O R D E R
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EFI
Type
2 Female Crimp Terminal Inserts.
Later style terminals for any Female EFI Plug Housing on this page. These terminals fit the above Female EFI plug housing and are typically crimped onto 14-22 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.  
S H I P P I N G N E E D S T O B E A D D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
S H I P P I N G N E E D S T O B E A D D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
S H I P P I N G N E E D S T O B E A D D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
S H I P P I N
G N E E D S T O
B E A D D E D O N L
Y O N E T I M E
P E R O R D E R
Shipping options
are also available at bottom of page: Click Here.
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S H I P P I N G N E E D S T O B E A D D E D O N L Y O N E T I M E P E R O R D E R
Shipping options
are also available at bottom of page: Click Here.
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EFI Type 1 Female Crimp
Terminal Insert.
Earlier style terminals for any Female EFI Plug Housings on this page. These terminals fit the above Female EFI plug housing and are typically crimped onto 14-22 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.  
S H I P P I N G N E E D S T O B E A D D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
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EFI
Type
2 Female Crimp Terminal Insert.
Later style terminals for any Female EFI Plug Housing on this page. These terminals fit the above Female EFI plug housing and are typically crimped onto 14-22 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. 
S H I P P I N G N E E D S T O B E A D D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
S H I P P I N G N E E D S T O B E A D D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
S H I P P I N G N E E D S T O B E A D D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
S H I P P I N G N E E D S T O B E A D D E D O N L Y O N E T I M E P E R O R D E R
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S H I P P I N G N E E D S T O B E A D D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
S H I P P I N
G I S N E E D E D O N
L Y O N E T I M
E P E R O R D E R
Shipping options
are also available at bottom of page: Click Here.
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| VOLVO
Sealed Connector Plugs and Bullet Terminal Inserts for Volvo Engine Harnesses |
| FEMALE BULLET PLUGS |
MALE BULLET PLUGS |
| 8-Pole
Female Volvo BULLET Plugs |
8-Pole
MALE Volvo BULLET Plugs |
| 1-Pole Female Volvo BULLET
Plugs |
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| 2-Pole
Female Volvo BULLET Plugs |
2-Pole
MALE Volvo BULLET Plugs |
| 3-Pole
Female Volvo BULLET Plugs |
3-Pole
MALE Volvo BULLET Plugs |
| 4-Pole
Female Volvo BULLET Plugs |
4-Pole
MALE Volvo BULLET Plugs |
| Female BULLET Wire Pigtails |
MALE BULLET Wire Pigtails |
| BUTT SPLICE Crimp Terminals | |
| 2-Speed
Volvo Cooling Fan Relay Connectors and Terminals |
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| 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 |
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S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
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Click photo for
larger image
MALE 8-Pole Plug
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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 |
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S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
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FEMALE 2-Pole Plug
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Volvo
FEMALE 2-pole
sealed bullet connector housing. Housing WITHOUT wire terminals/pigtails. 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. Housings WITH pigtails are offered below: CLICK HERE. Also female bullet terminal pigtails are offered separately below: CLICK HERE. These housings are commonly marked STD 7614.31. That's not a part number. That same number appears on SEVERAL DIFFERENT Volvo harness connectors. 
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S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
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FEMALE 2-Pole Plug with Pigtails
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Volvo
FEMALE 2-pole
sealed bullet connector housing. Connector Housing WITH Pigtails. For common Volvo engine harnesses using a 2-pole female plug for the following: Rear differential vehicle speed sensor (VSS). Some engine sensors. Some under-hood fender harness plugs or firewall harness plugs. |
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S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
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MALE 2-Pole Plug
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Genuine Volvo MALE 2-pole
sealed BULLET connector housing. For common Volvo engine harnesses. These use the below MALE sealed bullet terminal inserts for a weatherproof connection. This is the housing only. Male bullet terminal insert pigtails are sold separately below: CLICK HERE. |
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S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
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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. Female bullet terminal insert pigtails are sold separately below: CLICK HERE. |
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S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
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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 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. Male bullet terminal insert pigtails are sold separately below: CLICK HERE. |
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S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
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FEMALE
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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. It's marked STD 7614.31 (NOTE: That number is not a part number. The same number appears on several different Volvo harness connectors). COMMON USES: 740/940 models: Radio Noise Suppression Relay Plug and Cooling Fan Relay Plug. 240 models: Cooling Fan Relay Plug.
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  This
plug is commonly used for the Radio Noise Suppression Relay (740, 780,
940) and Auxiliary Cooling Fan Relay (240, 740, 940).The female wire insert PIGTAILS for this plug are available below: CLICK HERE. |
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S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
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FEMALE |
Genuine Volvo FEMALE
4-pole sealed bullet connector housing. This PLUG HOUSING comes FULLY ASSEMBLED with WIRE PIGTAILS. COMMON USES: 740, 780, 940 models: Radio Noise Suppression Relay Plug and also Cooling Fan Relay Plug. 240 models: Cooling Fan Relay Plug. |
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WIRE SIZES: Most colors are
standard 1.0 mm², which is comparable to
approximately AWG 17-18 (18 gauge). If you
need a larger wire, some Fat wire colors
are available.
Fat Yellow, Fat Red, Fat Black, Fat Blue or Fat Brown: These fatter wires are available in 2.5 mm², which is comparable to approximately AWG 13-14 (13-14 gauge). 2.5 mm² is the fattest wire size available for these pigtails. | |||||||
S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. | |||||||
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MALE
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Genuine
Volvo MALE 4-pole sealed bullet
connector housing used in some Volvo engine harnesses.
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 MALE bullet terminal insert pigtails are sold separately below: CLICK HERE. |
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S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
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FEMALE
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FEMALE BULLET 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)
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S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
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MALE
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MALE BULLET
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,
which is comparable to approximately AWG 17-18 (18
gauge). If you need a larger wire, you may choose the Fat Yellow, Fat Red, Fat Black, Fat Blue or Fat Brown, which uses 2.5 mm² wire, which is comparable to approximately AWG 13-14 (13-14 gauge). That is the fattest wire size available for these pigtails. 
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S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
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BUTT SPLICE CRIMP TERMINALS: Insulated butt spices are available for your general wiring needs. TWO SIZES: RED: Small for 18 to 22 gauge wire (suitable for above standard wire pigtails with 1.0 mm² wire). BLUE: Large for 14 to 16 gauge wire (suitable for FAT wire pigtails in this section with 2.5 mm² wire). CRIMPING GUIDE PAGE: CLICK HERE |
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S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. | |||||||
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FEMALE
Comes assembled as pictured. |
Special FEMALE
1-POLE BULLET Sealed 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. 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, Fat Red, Fat Black or Fat Blue: Fatter 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. |
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<<<
If you're looking for the correct sealed connectors
for a Volvo
(Bosch) fuel pump, then these are the correct connectors.
And if you need this connector for a pump, I strongly recommend the fatter wire, like the 2.5 mm² wire offered below, because a fuel pump draws a higher level of amps and the wires going to it are usually pretty long. |
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<<<
If you're looking for the correct sealed connector
for this Oil Pressure Sender
on 240 or 700/900 model with B230F/FT engines, then this is the correct connector.
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<<<
If you're looking for the correct Volvo plug to mate with the opposite one like THIS ONE under your hood, this is the correct connector. |
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S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
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| Volvo 2-Speed Cooling Fan
Relay Connectors 58 Series Connectors and Terminals | |||||||
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Here are the correct sealed connectors used by Volvo for the Volvo
2-Speed Cooling Fan Relay found in 1990s
850 and 900 series models. These connectors are
WEATHER SEALED by an internal o-ring in the relay port and a rear cable
seal
that is inserted into the back of the connector
during assembly. So if you're
making repairs or if you're using a Volvo 2-speed
relay on another project, the correct
matching connectors can be found below. |
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2-Pole Female Connector
for speed #1 and #2 power output. It uses special
9.5 mm large female 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). |
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1-Pole Female Connector
for primary voltage power input. It also uses the
same special 9.5 mm large female 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. |
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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 for the main engine harness power supply. This connector is featured here because it MATES to the FEMALE connector shown above, which is also used in other models. The special crimp terminal is 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. |
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58 Series Connectors and Parts ORDER BELOW |
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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 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). |
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S H I P
P I N G I S N E E D E D
O N L Y O N E T I M
E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
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| Special Terminals for 240 Instrument Cluster Round Bullet Plugs |
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| Standard Relay Plugs and Terminals |
| 5-Pole Relay Plug |
| 5-Pole Interlocking Relay Plugs |
| 6-Pole Fuel Relay Plug |
| .250 inch (6.3 mm) Plug
Terminals |
| 240 Headlight Step Relay Plugs |
S H I P P I N
G I S N E E D E D O
N L Y O N E T I M
E P E R O R D E R
Shipping options are also available at bottom of page: Click Here.
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 5-Pole Interlocking RELAY PLUG
SOCKETFits 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.
S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here.
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IN STOCK
$3.00 each.
S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here.
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Two types:
S H I P P I N
G I S N E E D E D O
N L Y O N E T I M
E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
.250 inch (6.3 mm) FEMALE terminals. For all above relay plug housings.
S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
| .250 inch (6.3 mm) Plugs and Crimp 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 "PIGGYBACK"
Terminals for Fuse Panels |
| .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
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| 8-Pole .250 inch Female
Plug |
| 8-Pole .250 inch MALE Plug |
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 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. bos0 ,30e S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
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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. S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
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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 S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
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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. bos0 ,30e S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
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.250 inch (6.3 mm) FEMALE terminals. For all above relay plug housings.
S H I P P I N G I S N E E D E D O N L Y O N E T I M E P E R O R D E R
Shipping options are also available at bottom of page: Click Here. |
S H
I P P I N G I S N E E D E D
O N L Y O N E T I M
E P E R O R D E R
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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. ORDER HERE: S H
I P P I N G I S N E E D E D
O N L Y O N E T I M
E P E R O R D E R
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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. ORDER HERE:
S H
I P P I N G I S N E E D E D
O N L Y O N E T I M
E P E R O R D E R
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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. ORDER HERE: S H
I P P I N G I S N E E D E D
O N L Y O N E T I M
E P E R O R D E R
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 2-Pole
FEMALE Plug Housing for above .250 inch (6.3 mm)
female terminal.Plug housing only. $0.80 ea. ORDER HERE:
S H
I P P I N G I S N E E D E D
O N L Y O N E T I M
E P E R O R D E R
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 2-Pole
MALE
Plug Housing for above .250 inch (6.3 mm)
male terminal.Plug housing only. $0.80 ea.
S H
I P P I N G I S N E E D E D
O N L Y O N E T I M
E P E R O R D E R
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 4-Pole FEMALE
Plug Housing for above .250 inch (6.3 mm)
female terminal.Plug housing only. $1.40 ea.
S H
I P P I N G I S N E E D E D
O N L Y O N E T I M
E P E R O R D E R
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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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I P P I N G I S N E E D E D
O N L Y O N E T I M
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 6-Pole MALE
Plug Housing for above .250 inch (6.3 mm)
male terminal.Plug housing only. $3.00 ea. ORDER HERE:
S H
I P P I N G I S N E E D E D
O N L Y O N E T I M
E P E R O R D E R
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 8-Pole FEMALE
Plug Housing for above .250 inch (6.3 mm)
female terminal.Plug housing only. $3.00 ea. ORDER HERE:
S H
I P P I N G I S N E E D E D
O N L Y O N E T I M
E P E R O R D E R
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 8-Pole MALE
Plug Housing for above
.250 inch (6.3 mm) male terminal.Plug housing only. $3.00 ea. ORDER HERE:
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I P P I N G I S N E E D E D
O N L Y O N E T I M
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| Headlight Plugs and Terminals |
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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: https://www.240turbo.com/volvo240mods.html#headlightrelayharness $1.50 each, IN STOCK ORDER HERE: S H I
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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. It has the correct tab for locking into place in the above flag headlight plug housing. If you need to use bigger 10 gauge wire for your headlights, I recommend changing to the straight type plug below. $0.45 each, IN STOCK ORDER HERE: S H I
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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: https://www.240turbo.com/volvo240mods.html#headlightrelayharness PRICE: $2.40 each. IN STOCK ORDER HERE: S H I
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O N L Y O N E T I M
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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 ORDER HERE: S H I
P P I N G I S N E E D E D
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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: https://www.240turbo.com/volvo240mods.html#headlightrelayharness .312 Female Straight Terminal for large 10 Gauge wire PRICE: $0.75 each. IN STOCK ORDER HERE: S H
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| .375 inch (9.5 mm) Terminals |
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ORDER HERE: PRICE: $0.75 each, either size. IN STOCK S H I
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ORDER HERE: PRICE: $0.75 each, IN STOCK S H I
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SMALL OVERCRIMP PIC 
LARGE OVERCRIMP 
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OVERCRIMPS
for
using Oversized Wire on Undersized Terminals Hard to find open barrel 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.
ORDER HERE: Quantity Discount: 10 or more. Small: $0.20 each. Large: $0.40 each. Quantity Discount: 50 or more. Small: $0.15 each. Large: $0.30 each. S H I
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| 3.5 mm
Bullet Plugs and Terminals (non-sealed). Typically used for under-dash wiring. |
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 3.5 mm MALE
Bullet Terminal. Fits above 4-pole Plug
HousingTerminal only. Plug housing not included. $0.50 each. IN STOCK ORDER HERE:b0.12e S
H I P P I N G I S N E E D E
D O N L Y O N E T I M
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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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H I P P I N G I S N E E D E
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 4-pole Blue FEMALE Plug HousingHousing only. Terminals not included. For below 3.5 mm female bullet terminals. This plug was found in the under dash harness for 1986 and later 240. $4.00 each. IN STOCK bos0,1 5e
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H I P P I N G I S N E E D E
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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 ORDER HERE: S
H I P P I N G I S N E E D E
D O N L Y O N E T I M
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| Terminal Blocks |
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Terminal blocks like
these 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 row. So this means it's possible to use one block for distribution to multiple circuits or it can be set up as an all-in-one commone block. |
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I used some of these when I re-wired my dash in my 242 Turbo. In this photo, one 8-row block 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 separate ground points all over in different places. You can see that project here: https://www.240turbo.com/classicair.html#terminalblocks. | ||||||||
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| THESE MAY BE ORDERED
BELOW |
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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. |
| ALL SIZES IN STOCK UNLESS OTHERWISE NOTED | ||||
| SIZE I/D | INTERNAL DIMENSION | WALL THICKNESS | PRICE PER FOOT | ORDER HERE: |
| 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
(weight approx 0.12 oz/ft) |
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| 1/4 inch | ID:
0.250 inch (6.3 mm) |
Wall thickness:
0.020 inch (0.5 mm) |
$0.70 per foot (weight approx 0.18 oz/ft) |
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| Please proceed to SHIPPING
below when done shopping: CLICK HERE |
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| 5/16 inch | ID:
0.313 inch (8.0 mm) |
Wall thickness:
0.025 inch (0.63 mm) |
$0.80 per
foot ( weight approx 0.25 oz/ft) |
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| 3/8 inch | ID:
0.375 inch
(9.5 mm) |
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SMALL: 14-18 gauge wire recommended. $0.40 each
LARGE: 10-12 gauge wire recommended. 
