What's the Story on Volvo Harnesses?
Beginning in 1998, in my spare time, I began searching some of Southern California's salvage yards for slightly USED, but EXCELLENT Volvo engine wire harnesses for 1980 to 1987 Volvo 200 and 700 models (and a few other years on rare occasions).  The original harnesses in these cars were made with a defective plastic insulation that badly deteriorated after years of exposure to engine heat.  The owners were then forced to have them replaced, unless they were fortunate and the defect occurred during the warranty (I have only heard from ONE owner over the years that had the replacement covered).

An engine wire harness is the part of the wire loom that goes to the many different points on the engine, such as the starter motor, alternator, sensors, fuel injection, etc.  On some cars, such as with several 240 models, the engine harness will extend through the firewall to a computer.  On others it might connect to a different body harness at the firewall or a fender, which then continues onward to other parts of the car. 

You will see the term "later replacement harness" used throughout this site.  This term refers to a Volvo wire harness specifically produced to replace the original defective harness.  A later replacement harness is not just another original Volvo wire harness.  The defect was corrected eventually and the replacement harnesses had good insulation.  So if you owned, for example, an '85 240 with an original rotten main engine wire harness, you wouldn't be forced to spend all that money to install a harness that would eventually fall apart again like the original one did.  Instead, a later replacement harness was made available, manufactured with superior wiring insulation and intended to literally last the life of the car. 

All later replacement harnesses  were given NEWER PART NUMBERS (there are only a couple exceptions).  These newer numbers were issued by Volvo, so there will not confused with the bad ones.  This new part number (always visible on a newer harness) is how you can tell it is a later replacement harness. 

Unless otherwise noted... ALL VOLVO HARNESSES I offer for sale for 1980 through 1987 models are either....
USED later replacement harnesses (IF AVAILABLE)
or NEW Genuine Volvo Harnesses
or NEW Aftermarket Harnesses. 

Any USED harnesses I offer were acquired from wrecked Volvos, in which the engine wire harness had been already been replaced before it was wrecked.

I have searched for these harnesses in wrecked Volvos because when I find a nearly new one, someone can still get some use for it.  I'm very picky about quality, since there are many used harnesses out there that are beaten up.  If you're looking for a GOOD used harness for your 1980 though 1987 Volvo, you should be very careful about where and who you get it from.  I often see used harnesses in salvaged cars that are damaged, burnt or melted....  These are the ones I pass up.  As you will see if you make a purchase, I sell only quality.  For EVERY used harness I offer,  I guarantee 100% total satisfaction.

A Little History about Bad Volvo Harnesses:
The factory original engine harnesses installed in all Volvos during the 1980 through 1987 model years started to disintegrate after a few years of exposure to engine heat.  The insulation on the individual wires would get soft and crumble away, eventually leaving exposed wires to short out and cause all kinds of problems with electronic systems.  THIS PROBLEM IS CAUSED BY HEAT attacking the defective insulation over years, and was accelerated in turbocharged cars due to the much higher heat conditions in the engine bay. 

This problem generally DID NOT plague pre-1980 Volvos, nor the 1988 and later cars, which all seem to have good wire insulation.  Volvo recognized and was able to correct this problem for all 1988 and later models.

If your 1980 to 1987 Volvo still has the original engine harness and you don't see any such obvious damage yet, please don't assume you got off lucky.  I have inspected thousands of 1980 through 1987 Volvo harnesses in wrecking yards and elsewhere, and unless the car had very few miles, the original engine harness pretty much went bad 100% of the time.  This often happens in places where it is not so obvious too, such as deep inside the protective vinyl covers of the harness.  Many customers have told me about their discoveries when removing old harnesses. 
Some people have cut open the harness coverings, only to find multiple bare wire strands where there should be bundles of colored wires. 

If you have one of these Volvos, this could very well be the cause of intermittent failures.  These harnesses connect to such components as the engine sensors, alternator, starter motor, fuel injectors, throttle position switch, idle control valve, mass air sensor, fuel pump relay, oxygen sensor, ground points, control pressure regulator and cold start injector.

What about Ignition Harnesses in 240's?
Please keep in mind the Ignition Wire Harness is a separate part on pre-1988 4-cylinder 240's and is not included when you buy an "Engine Harness." The GOOD NEWS is I have found that 240 Ignition Harnesses were typically not found to be defective as often as Engine Harnesses were.  This means Ignition Harnesses usually last longer (maybe because they are more sheltered from heat).  

The 740/760 Series:
When it came to the 740/760 series, Volvo designed their wiring systems a little differently than 240's, although the 1980 through 1987 models experienced the same defects.  The below diagram illustrates the most prominent under-hood harnesses for the 740/760 cars:
1. Engine Harness
2. Left Side Suspension Tower Harness (or Fender Harness)
3. Right Side Suspension Tower Harness (or Fender Harness)
Of course the Engine Harness (shown as #1) is the one that goes bad on these cars first. The right and left Fender Harnesses usually survive much longer.  If you find damage to fender harness you should consider making some repairs as Fender Harnesses are NOT AVAILABLE as later replacement harnesses, and they are very, very expensive to buy new if you can find them (usually around $500 each).  

The general Volvo Engine Harness defect was discovered several years after production as wire harnesses started crumbling in Volvos by the mid-1980's, beginning with the '80 models.  By the end of the 1987 model year, Volvo cured the problem in their production runs.  From the 1988 model year to present, all new harnesses, including the new replacement ones for pre-88 cars, had an improved wire insulation that would not disintegrate like the old harnesses did.  
All of the later production harnesses made to replace the bad ones were assigned new part numbers, making it easy to recognize an original harness versus a later replacement. 

Over the years, some bad harnesses were replaced with new upgraded ones by Volvo dealerships, sometimes as good will gestures and sometimes for those owners lucky enough to have the defect discovered during their warranty periods.  But most Volvo owners have not been so lucky and have been faced with either paying big bucks for a dealer to replace the engine harness, patching the harnesses themselves, or possibly junking their Volvo.  There are still many Volvos on the road that still have the old, crumbling harnesses.  A later replacement harness is a very good investment if you plan to keep your car on the road.

It does not appear Volvo ever fully owned up to their responsibility to owners of these cars.  If they did then you probably wouldn't be reading about it here.  What they did, however, was lower the prices of many new replacement harnesses after the news of this disaster became public and appeals were made by members of the Volvo Club of America and other Volvo enthusiasts around the world.

1. --All are Genuine Volvo or Aftermarket replacement harnesses (each is clearly stated) with the later production Volvo part numbers on them.  These harnesses do NOT deteriorate when exposed to heat like the original ones did.
2. --When it comes to USED harnesses, I am very picky...  I choose only the best replacement harnesses out there.  These harnesses were chosen for their near new quality, as many of them appear as if they were installed a very short time before the car was salvaged.  I pass up a LOT of newer harnesses on 1980 through 1987 Volvos that just don't measure up, due to age or damage.
3. --All USED harnesses come with a FULL 100% SATISFACTION GUARANTEE.  There is no better guarantee on the planet!  This means if a harness does not meet your expectations in every way, it may be returned for a full refund (see Return Policy below).  I value my customer relations and my good reputation.
4. --The best reason....  Used replacement harnesses are always A LOT CHEAPER than the new ones.
5. --Most harnesses come with COMPREHENSIVE COLOR CONNECTION DIAGRAMS (designed by me) to assist you with installation.  A small sample of the comprehensive color diagrams I have created is below....