1986-1993 Volvo 240 Distributor Cap Replacement

A dirty or broken distributor cap may lead to a...

iFixit Library 1986-1993 Volvo 240 Moderate 30 minutes Guide 9210

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Guide overview

Before you begin

A dirty or broken distributor cap may lead to a number of ignition problems in your Volvo 240. Consult your owner's manual for a regular interval to inspect your distributor cap for damage, excess wear, or carbon buildup.

Step 1

Repair step

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The distributor cap is located next to the engine and has all of the spark plug wires connecting to it.
Pull straight up on the ignition coil wire in the center of the distributor cap to disconnect it.

Step 2

Repair step

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Connect the spark plug wires to the new distributor cap one at a time. Mixing up the order will result in the engine not firing properly or at all.
Pull straight up on the boot of the first spark plug wire to disconnect it from the distributor cap.
Be sure to pull on the boot and not the wire itself. Spark plug wires are quite fragile and may break easily.

Step 3

Repair step

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Install the spark plug wire onto the new distributor cap and make sure it is seated properly.
Continue to transfer each spark plug wire to the new distributor cap, maintaining the same arrangement of wires on the cap.
Once all of the spark plug wires have been installed on the new distributor cap, set the cap aside.

Step 4

Repair step

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TOOL USED ON THIS STEP 6-in-1 Screwdriver Referenced by the iFixit guide

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Use a flathead screwdriver to release the clip securing the distributor cap.
Only one side of the distributor cap has a spot for the clip to rest. The new cap must be installed in the same orientation.
Remove the old distributor cap.
When installing the new distributor cap, don't forget to reconnect the center ignition coil wire.