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Plugs, Connectors, Terminals, Solutions. PAGE 2  |
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Plugs, Connectors, Terminals, Solutions. PAGE 2 |
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UPDATED: September 3, 2025
CONTACT
SHIPPING
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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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| 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. This connector uses special large 9.5 mm female terminals. These special crimp terminals are designed for up to 10 gauge cable. Terminal amp rating: 40 to 60A 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 large 9.5 mm female terminals. These special crimp terminals are designed for up to 10 gauge cable. Terminal amp rating: 40 to 60A 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.
NOTE: This connector is NOT used with a fan relay. It's used in other locations under the hood of 850 and 960 models, mostly 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 places and models. The special crimp terminal is designed for up to 10 gauge cable. Terminal amp rating: 40 to 60A 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 and Shopping Cart 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 and Shopping Cart are also available at bottom of page: Click Here.
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 5-Pole Female
INTERLOCKING Relay PlugFits all STANDARD 4 or 5-pole mini relays. These are usually up to 40 amps. Plug uses .250 inch (6.3 mm) female locking terminals (offered below). Will NOT fit a 5-pole HIGH CURRENT relay further below. Click here for tips on removing wire connector inserts from these sockets. IN STOCK $3.00 each
Shipping options are also available at bottom of page: Click Here. |
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IN STOCK
$4.00 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 and Shopping Cart 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 and Shopping Cart 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 and Shopping Cart are also available at bottom of page: Click Here. |
| .250 inch (6.3 mm) Plugs and Crimp Terminals |
| 1-Pole .187 inch Female PLUG |
| 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 (WHITE) 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. bos0 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 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. ,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. ,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 and Shopping Cart 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: SMALL IN STOCK ORDER HERE: LARGE IN STOCK 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. ORDER HERE: IN STOCK 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. ORDER HERE: IN STOCK 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. ORDER HERE: IN STOCK 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. ORDER HERE: IN STOCK 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. ORDER HERE: IN STOCK 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. ORDER HERE: IN STOCK 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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 6-Pole FEMALE
Plug Housing for above .250 inch (6.3 mm)
female terminal.Plug housing only. $3.00 ea. ORDER HERE: IN STOCK 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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 6-Pole MALE
Plug Housing for above .250 inch (6.3 mm)
male terminal.Plug housing only. $3.00 ea. ORDER HERE: IN STOCK 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: IN STOCK 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: IN STOCK 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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| Headlight Plugs and Terminals |
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Headlight Flag Plug Housing
(3-poles). Fits Standard or H1 or H4 type (also 9003). Uses .312 inch (7.9 mm) FLAG style 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 headlight harnesses: HEADLIGHT PAGE https://www.240turbo.com/headlight.html $1.50 each, IN STOCK 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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.312 inch (7.9 mm) Female
Locking FLAG Style 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
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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Headlight Straight Plug Housing
(3-poles). Fits Standard or H1 or H4 type (also 9003). Uses .312 inch 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 headlight harnesses: HEADLIGHT PAGE https://www.240turbo.com/headlight.html PRICE: $2.40 each. IN STOCK 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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.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. 12-16 AWG wire.  <<< Do you need
to use this terminal with BIGGER 10 GAUGE WIRE
to make an ultimate headlight harness? It is possible using an
OVERCRIMP (see photo). OVERCRIMPS are
available a bit further below or CLICK HERE. .312 Female Straight Terminal 12-16 AWG IN STOCK 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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.312 inch (7.9 mm) Female Terminal for above STRAIGHT Headlight Plug. Largest Size: Fits 10-12 AWG wire. AMP RATING: 28 amps. Large 10-12 AWG wire.  These special larger cable terminals
were VERY hard to find. These fit the black straight
headlight plug housing shown (same as above), but these will fits
large 10
gauge wire as shown in photo. There is no
other .312 inch headlight terminal that will hold 10 gauge
wire. FITTING NOTE: This terminal fits this 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. I've used these and that will not happen after being plugged in. If the lack of a locking device 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 headlight harnesses: HEADLIGHT PAGE https://www.240turbo.com/headlight.html .312 Female Straight TERMINAL for large 10 Gauge wire PRICE: $0.75 each. IN STOCK 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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| .375 inch (9.5 mm) Terminals |
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ORDER HERE: FEMALE
PRICE: $1.10 each, either size. IN STOCK 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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ORDER HERE: MALE
PRICE: $1.20 each IN STOCK 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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| Overcrimps for Large Wire |
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 be a life saver. Overcrimps will not fit FLAG style terminals.
ORDER HERE: Proceed to SHIPPING OPTIONS below after shopping. Quantity Discount: 10 or more. Small: $0.20 each. Quantity Discount: 10 or more. Large: $0.40 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
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| 3.5 mm
Bullet DASH 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. $0.70 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
E P E R O R D E R
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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 bos0.12e 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
E P E R O R D E R
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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. $6.00 each. IN STOCK bos0,1 5e ORDER HERE:
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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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 3.5 mm
FEMALE Bullet Terminal for above 4-pole Plug
Housing Terminal only. $0.70 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
E P E R O R D E R
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| Terminal
Blocks NO LONGER AVAILABLE HERE |
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Eaton Bussmann 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 common bus block. |
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I used some of these
when I re-wired my dash in my 242 Turbo. In this photo, I used one 8-row
block to consolidate all 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 proj ect here: https://www.240turbo.com/classicair.html#terminalblocks. |
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These are NO LONGER AVAILABLE IN MY SITE.
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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) |
$0.70 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) |
$1.00 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) |
$1.10 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) |
$1.30 per
foot ( weight approx 0.25 oz/ft) |
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3/8 inch OUT OF STOCK |
ID:
0.375 inch
(9.5 mm) |
Wall thickness:
0.025 inch
(0.63 mm) |
$1.50 per
foot OUT OF STOCK (weight approx 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) |
$1.70 per
foot ( weight approx 0.39 oz/ft) |
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| Please proceed to SHIPPING below when done shopping: CLICK HERE | ||||
| 1/2 inch | ID:
0.500
inch (12.7 mm) |
Wall thickness:
0.025
inch (0.63 mm) |
$1.80
per foot ( weight approx 0.45 oz/ft) |
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| 9/16 inch | ID:
0.563
inch (14.3 mm) |
Wall thickness:
0.030
inch (0.76 mm) |
$2.00
per foot ( weight approx 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) |
$2.10
per foot ( weight approx 0.82 oz/ft) |
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| Please proceed to SHIPPING below when done shopping: CLICK HERE | ||||
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3/4 inch LIMITED SUPPLY |
ID:
0.750
inch
(19.0 mm) |
Wall thickness:
0.035
inch (0.89 mm) |
$2.50
per foot ( weight approx 1 oz/ft) |
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| 7/8 inch LIMITED SUPPLY |
ID: 0.875 inch (22.2 mm) | Wall thickness: 0.035 inch (0.89 mm) |
$2.80
per foot ( weight approx 1.1 oz/ft) |
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1 inch LIMITED SUPPLY |
ID:
1.00 inch
(25.4 mm) |
Wall thickness:
0.035
inch (0.89 mm) |
$2.00 per foot (close out price) ( weight approx 1.2 oz/ft) |
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To View Cart or Check Out please click below button:
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| Additional Purchase or Shipping Payment (This will allow you to add an additional charge to your Shopping Cart order) The below shipping buttons are for use with my Shopping Cart. This can be used to add an extra shipping charge or payment of any amount to any order. So if you need to add an extra amount for an unusual order, this will work. View Cart or Check Out:
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SMALL: 14-18 gauge wire recommended. $0.60 each
