Volvo P1800 spark plugs and cable change, and brake booster repair too

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Yesterda while driving on the road of two lanes, as car on the right suddenly turn to my lane and I have to do a bit of emergency braking. The tyres skipped a bit and then only I understand by first hand that this car cannot compare to modern car ABS disc brake braking system. My RCZ is able to brake much more confidently at close distance, while I will have to be much more careful and give more tolerance and room distance with my Volvo.

I bought a new set of spark plugs and decided to give it a change. Bought also the spark plug changing tools (21mm hexagon size).

Changing the spark plugs is not so easy or difficult, but requires quite a bit of strength. Due to the overwhelming wiring from the previous owner, there is little room to access to the spark plugs. The ignition cables were way too long, and there are air conditioning hose and brake booster vacuum hose routing in between.

I was able to remove and changed all the 4 spark plugs, and found that the old spark plugs to be of different burning condition. Two seems quite dark or wet. Looks like the fuel are not fully burnt.

During the process, one ignition coil or broken. I am not sure of it is because of my careless action or because it is already fragile. I also noticed that one of the 4 cables is of different head. What a messy plug cables. I have wanted to change the cable from day 1, but unsure of the suitable one. Getting a set from USA is possible but not exactly cheap. I have a feeling that I can get better and cheaper compatible cables locally, so that delay my purchase.

Sine oone of the cable has broken, I can’t delay the purchase further. I checked online and went to a spare part shop to get a set of spark plug cables including a coil cable. I wanted to get a red one initially but there is only blue one suitable, I think blue is fine as well. RM70 for the set. Reasonable price for a good quality cable.

The ccable looks like of good quality, silicone type and thicker than the existing one. Most importantly, it is NOT over in length!

Changing the cables is easier than the spark plugs. A bit of routing to make sure that it does not hit other parts of the car.

Here’s how the cable connecting to the distributor.

By the way, besides breaking one of the ignition plug cable, I also broke the vacuum seal to the brake booster. The seal was already broken last time, and the previous owner used silicon to cover it up. Not a permanent job for sure and while unplugging the plug cable, the silicon that sealed the valve grommet rubber to the brake booster got leaked. I can hear hissing sound from it after I turn off the engine. Meaning that air is being sucked into the brake booster.

From the above photo, it was clear that the previous owner tried to seal it by putting some glue or silicone glue over it. Bad job.

I spent quite a while finding the replacement valve grommet rubber online. The cheapest I found is actually from ebay, just USD9.90 for not just the rubber but also the valve. Free shipping within USA. I was about to make the purchase but it will still take at least a week or two before I can get it and install to my car. I don’t want to wait so long not having to drive it, so I decided to check it out at my local spare part shop.

This is what I bought from the first visit. While it looks OK, but after fitting, I found it to be loose. A slight movement causes air to leak. Definitely not suitable.

I went back to the spare part shop for a replacement unit, with little hope and was planning to order from ebay later already. The boss searched and got me a thicker rubber, original Honda rubber as per the packaging, though is very old stock.

Without much hope, I went home and tried installing it. It was very tight fit into the brake booster. Good sign. Then it look me quite a bit of strength to insert the valve into it. Wow, really tight fit and it won’t leak for sure! I think it is even better than the original one which is much thinner.

I forgot to take photo of the rubber before installing, but here’s the result after installation. Don’t mind the black and yellow glue there from the previous owner poor DIY job. I have tried to clean up as much as I could.

I have also topped up the brake reservoir fluid with DOT 4 brake fluid. Hopefully there won’t be any leak and reduction in the brake master cylinder later. I shall continue monitoring this.