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Volvo Engine Harness
COIL REPAIR HARNESSES
960 - S90 - S40 - V40 - S60 - V70 - S80
O N - L I N E   V O L V O   H A R N E S S   S A L E S  A N D   A D V I C E   S I N C E   1 9 9 8

     UPDATED: July 22, 2017                       CONTACT       
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960 (and S90/V90) Coil Repair Harnesses (6 cyl)
5 Cylinder (1999-2007) Coil Repair Harnesses

4 Cylinder (2000-2004) S40, V40 Coil Plug Repair Kits 6 Cylinder (1999-2006) Coil Repair Harnesses

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COIL REPAIR HARNESSES for 960, S90, and V90 1992-98.
What's going on with 960, S90, and V90 engine wire harnesses?
Several years ago Volvo owners and Volvo service technicians begain noticing some problems with the main engine harnesses in 1992 and later Volvo 960, S90, and V90 models. These cars are equipped with the 6 cylinder 24 valve engine.  I began to get emails from them hoping for a solution. Volvo technicians had discovered that Volvo was demanding highly inflated prices for 960 main engine harnesses (up to $5,000). 

  This is a common issue and it is usually limited to the portion of the harness that goes to the 6 ignition coils under the top coil cover on the engine. 
This portion of the harness has a tendancy to malfunction.  The cause is due to prolonged exposure to the high engine temperatures under that coil cover.  The 2-pole plugs are literally falling apart after years of high heat
(see photos below)

When I first began hearing about this problem I began investigating a solution.  I had been been working with 240 and 740 harnesses for a lot of years, so I began looking for 960s in salvage yards and I took several apart to see what was going on in the harnesses. Clearly there were many 960s that were sent to salvage yards because of this easy-to-fix issue.
<<<  Here we have a couple salvage yard photos.  The first 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 1998. 







<<< At left is an original Volvo 960 COIL HARNESS section I removed from a 960.  As you can see, the coil connectors have begun deteriorating.

<<< The connectors will deteriorate until there is almost nothing left to hold and seal the connection.

<<<
Compare those to this photo of a new connector.







REPLACEMENT OPTIONS:
Until now, there were more limited options for a Volvo 960, S90 or V90 owner with this problem: 
1.  Replace the complete engine harness. This harness 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). I have been told some other years may be about $3000-$4000. 
2.  Have someone make repairs using junk yard parts or parts you might find from Volvo.
3.  Send the car to the junk yard.  This actually happens a lot.
And really there is no reason to replace an entire engine harness if only the 7 wire coil branch is damaged due to heat.  So at the request of a number of Volvo technicians, I began having new portions of this coil harness made so anyone can make these repairs. 

<<< In case it becomes helpful to you, here is a PDF of the circuit diagrams covering the 1992-1998 960 coils. 
Click to open or right-click and save.



This is the new Coil Repair Harness.
A new repair harness will solve the common coil connector problems
in any 960, S90 or V90.



This REPAIR HARNESS and INSTALLATION KIT will allow you to splice a new 6 COIL BRANCH into your existing main engine harness (only 7 wires need to be spliced) and it will replace the damaged section that goes to all 6 ignition coils.  This harness offers about 8 inches (20 cm) of extra wire length behind the cylinder head for splicing into your original engine harness. New Genuine Volvo connector housings are provided with this harness.
FULLY DETAILED INSTRUCTIONS WITH PHOTOS:
CLICK HERE (PDF 360 kb)

 
IN STOCK

Price: $165.00 each plus shipping.


Order Quantity: Option:
If shipping is not chosen above, please choose shipping below.





1999-2006 Volvo 6 Cylinder Coil NEW Repair Harnesses
1999-2006 Volvo with 6 Cylinders.

What's going on with 6 cylinder Volvo coil harnesses?
  As these cars age, deterioration of the coil plugs under the top coil cover on these engines is becoming more and more common. 
The cause is due to prolonged exposure to the high engine temperatures under the coil cover.  The failure of these 4-pole plugs will cause poor running and OBD failure codes. Using this Coil Repair Harness will allow the rest of your engine harness to remain intact.


This new REPAIR HARNESS and INSTALLATION KIT will allow you to splice a new 6 COIL BRANCH into your existing main engine harness (12 wires will need to be spliced) and it will replace the damaged section that goes to all 6 ignition coils. It includes butt splices and heat-shrink tubing. New original Volvo connectors are used in this harness.

FULLY DETAILED INSTRUCTIONS WITH PHOTOS:
CLICK HERE (PDF 930 kb)

 
In Stock

Price: $175.00 each plus shipping.


Order Quantity: Option:
If shipping is not chosen with this purchase above, please choose shipping below.

Questions or more info:
CONTACT
bos65e

VVT Connector Harness Pigtails
Available to order with coil harness purchase.
Some models will have a Variable Valve Timing (VVT) solenoid mounted under the coil cover. This solenoid is near the front of the engine near the timing sprockets.  A new connector plug with wire pigtails is available below if you decide to renew it when replacing the coil repair harness. You may re-use your old connector and wires, but you will need to remove the wires from your old coil harness bundle.

NEW VVT Connector with Wire Pigtail
If you find a different connector on your 6 cylinder car, please let us know.
Wire pigtail length is about 30 inches.

Price: $16.00 each plus shipping.  Available with coil repair harness purchase.








Order Quantity: Option:

If ordered with a repair harness or other item, separate shipping is not required. Shipping options are below if needed, click here.

bos8e






1999-2007 Volvo 5 Cylinder Coil NEW Repair Harnesses
1999-2007 Volvo Turbo and Non-Turbo, 40, 50, 60, 70 and 80 series with 5 Cylinders.

What's going on with 5 cylinder Volvo coil harnesses?
  As these cars age, deterioration of the coil plugs under the top coil cover on these engines is becoming more and more common. 
The cause is due to prolonged exposure to the high engine temperatures under the coil cover.  The failure of these 4-pole plugs will cause poor running and OBD failure codes. Using this Coil Repair Harness will allow the rest of your engine harness to remain intact.


This new REPAIR HARNESS and INSTALLATION KIT will allow you to splice a new 5 COIL BRANCH into your existing main engine harness (only 7 wires need to be spliced) and it will replace the damaged section that goes to all 5 ignition coils. It includes butt splices and heat-shrink tubing. New original Volvo connectors are used in this harness.

FULLY DETAILED INSTRUCTIONS WITH PHOTOS:
CLICK HERE (PDF 700 kb)

 
In Stock

Price: $175.00 each plus shipping.


Order Quantity: Option:
If shipping is not chosen with this purchase above, please choose shipping below.

Questions or more info:
CONTACT
bos65e

VVT or CVVT Connector Harness Pigtails
Available to order with coil harness purchase.
Later models will have Variable Valve Timing (VVT) or Continuous Variable Valve Timing (CVVT). There are solenoids mounted under the coil cover. Some models will have only one and some will have two. These solenoids are near the front of the engine behind the timing sprockets and there will be one or two connector plugs.  New connector plugs with wire pigtails are available below if you decide to renew them when replacing the coil repair harness. All plugs are unique, so they are not interchangeable.  You may re-use your old VVT or CVVT connectors and wire if you prefer, but you will need to remove the wires from your old coil harness bundle.

New Dual VVT Connectors with Wire Pigtail
Turbo models (or most likely T5 models) will usually have dual VVT sensors.
Wire pigtail length is about 30 inches.

Price: $20.00 per set plus shipping.  May be purchased with coil repair harness only.







Order Quantity: Option:

If ordered with a repair harness, separate shipping is not required. Shipping options are below if needed, click here.

bos10e

New Single VVT Connector with Wire Pigtail
Single Connector Type 1 (large)
Later non-turbo cars will usually have a single VVT sensor. There is information that suggests this plug came on the following Volvos.
V70: up to chassis number 171000.  V70XC: up to chassis number 48000.  S60: up to chassis number 92352.
Cars with chassis number outside these parameters may have Single Connector #2 below.
Wire pigtail length is about 30 inches.

Price: $16.00 each plus shipping.  Available with coil repair harness purchase.








Order Quantity: Option:

If ordered with a repair harness, separate shipping is not required. Shipping options are below if needed, click here.

bos8e

New Single VVT Connector with Wire Pigtail
Single Connector Type 2 (small)
Wire pigtail length is about 30 inches.

Price: $16.00 each plus shipping.  Available with coil repair harness purchase.









Order Quantity: Option:

If ordered with a repair harness, separate shipping is not required. Shipping options are below if needed, click here.

bos8e

New Single VVT Connector with Wire Pigtail
Single Connector Type 3 (small)
Wire pigtail length is about 30 inches.

Price: $16.00 each plus shipping.  Available with coil repair harness purchase.









Order Quantity: Option:

If ordered with a repair harness, separate shipping is not required. Shipping options are below if needed, click here.

bos8e






2000-2004 Volvo 4 Cylinder (S40, V40) NEW Coil Plug Repair Kits
2000-2004 Volvo S40 or V40 series Turbo and Non-Turbo with 4 Cylinders (2 coils).

What's going on with these 4 cylinder Volvo coil plugs?
  <<< As these cars age, deterioration of the coil connectors under the top coil cover on these engines is becoming more and more common. 
The cause is due to prolonged exposure to the high engine temperatures under the coil cover.  The failure of these 2-pole connector plugs will cause poor running and OBD failure codes. Using this Coil Connector Plug Repair Harness will allow you to repair only the coil plugs and leave the rest of your engine harness intact.



NEW Coil Plug Repair Kit
This new coil plug repair kit will solve the common coil connector problems in your S40 or V40.

This REPAIR KIT will allow you to splice two new coil connector plugs into your existing main engine harness (only 4 wires need to be spliced, all of them under the top engine coil cover).  It will replace the damaged plugs going to your existing two coils (as shown below).  
New original Volvo connector plugs s are provided (marked STD7614.31).
INSTALLATION INSTRUCTIONS (750kb PDF)

IN STOCK

Price: $30.00 each plus shipping.


Order Quantity: Option:
If shipping is not chosen above, please choose shipping below.






Separate shipping may be added here.
USA Shipping for all 4, 5 or 6 cyl Coil Repair Harnesses

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Priority Mail EXPRESS is ONE DAY in most cases.
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International Shipping for all 4, 5 or 6 cyl Coil Repair Harnesses
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