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960 ENGINE HARNESS PAGE
Volvo owners and service techs have been finding some problems with the
main engine harnesses in 1992-1997 Volvo 960 models equipped with the 6 cylinder 24 valve engine.
| Volvo 960/S90 Engine Harness Part
Number Collection (Additional PN's are being sought if you have any) 960 6 cyl. 24 Valve 960 92 9130023 or 9130429 (with EGR). 960 92-94 (6849711 old, 6849712 old), newer 9130022 or 9130428 or 9128642 (no EGR). 960 95 9442365 960 96 9128879 |
It is a common issue, that is apparently limited to the portion of the harness that goes to the 6 ignition coils under the coil cover (similar to the valve cover).
This portion of the harness has a nasty tendancy to malfunction.
The cause is due to prolonged exposure to the high engine temperatures under that coil cover.
The soft female bullet connector inserts (see photo) in the 2-pole connector housings literally fall apart after years of torture.
Here is what a
new female Volvo bullet connector insert looks like (the light colored
one). The black one is a male
insert, ignore it. 
Here we have a
couple salvage yard photos. The photo
on the left is a 1993 960. The second pic is a
1995. The coil configuation and harness connections under the
coil cover are identical in all models from 1992 through 1997. 
At
left is the original Volvo harness section we're talking about.
I pulled this one out of a '93. The soft bullet connectors were
beginning to
disintegrate on this one too. REPLACEMENT OPTIONS:
The main engine harness for a 960 is only available from a Volvo dealer at greatly inflated prices. I was quoted anywhere from $1,600 to over $5,000 for the engine harness only... that's NOT an exageration.
And really there is no reason to replace the entire engine harness if only one small branch is damaged due to heat. See the solution to this below.
Here is a PDF of the circuit diagram covering 1992-1997 960 coils.
There were NO changes during these years.
I've never owned a 960, so when I first began hearing about this problem I really didn't know if there was a solution. Then I began getting some emails, mainly from Volvo techs who were hoping for a reasonable solution. I've been working with Volvo harnesses for a lot of years, so I began taking apart junkyard 960s to see what was going on. Clearly there were some 960s that were junked because of this easy to fix issue, because there was nothing else wrong with many of the ones I found in salvage yards.
Here's the Solution! This REPAIR HARNESS and INSTALLATION KIT will allow you to splice a new branch into your existing main engine harness and it will replace the damaged section that goes to the ignition coils. FULLY DETAILED INSTRUCTIONS WITH PHOTOS INCLUDED. OUT OF STOCK Your price: $120.00 ea. plus shipping. After
adding to cart, please choose
shipping below.
|
Step #3: Click below to View Cart or Check Out. |
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