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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 in the 2-pole plug housings literally fall apart after years of torture (see photo below).
<< Here is
what a
new Volvo female bullet insert looks like (the light colored
one on the right). The black one is a male
insert. Ignore it for this discussion. 
<< Here
we have a
couple salvage yard photos. The photo
on the left is a 1993 960. The second photo 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. 
<< Often the
connectors will deteriorate until
there is almost nothing left to hold the connection.REPLACEMENT OPTIONS:
The complete engine harness for a 960 is only available from a Volvo dealer at greatly inflated prices. When I checked, I was quoted over $5,000 for the engine harness for a 1996 960 (Volvo PN 9128879).
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.
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 seeing a lot of these in their shops and 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 in theirs. 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.
The 960 Solution! This REPAIR HARNESS and INSTALLATION KIT will allow you to splice a new COIL BRANCH into your existing main engine harness (7 wires) and it will replace the damaged section that goes to the 6 ignition coils. This harness offers about 7 inches (18 cm) behind the cylinder head for splicing. FULLY DETAILED INSTRUCTIONS WITH PHOTOS INCLUDED. Temporarily OUT OF STOCK Price: $150.00 each plus shipping. After
adding to cart, please choose
shipping below.
|
 2-POLE
FEMALE CONNECTOR SOCKET HOUSINGSThe above harness does not come with new gray plastic connector housings. You may use your existing ones and save some money. This usually works fine. However, if yours are damaged and you need new ones, I have a limited supply of brand new genuine Volvo connector housings. Price: $4.00 each IN STOCK After adding to cart, please choose shipping below. |
Step #3: Click below to View Cart or Check Out. |
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