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COIL REPAIR HARNESSES
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     UPDATED: July 19, 2018                       CONTACT       
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960 (and S90/V90) Coil Repair Harnesses (6 cyl 1992-98)
5 Cylinder (1999-2011) Coil Repair Harnesses
4 Cylinder (2000-2004) S40, V40 Coil Repair Harnesses 6 Cylinder (1999-2006) Coil Repair Harnesses
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Custom replacement COIL REPAIR HARNESSES for
Volvo 960, S90, and V90 1992-98.

Why do coil harnesses need to be replaced in Volvo cars?
Years ago Volvo service technicians begain noticing severe problems with the main engine harnesses (near the coils) 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 these concerned technicians.
Volvo technicians were dismayed after discovering these problems and then finding that Volvo was demanding highly inflated prices for 960 main engine harnesses (up to $5,000 each). 

  This has become a COMMON PROBLEM, 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 at 960 models in salvage yards. I took several apart to see what was going on in the harnesses. It certainly appears there were many 960s that were sent to salvage yards because of this easy-to-fix issue.
Volvo 1992-98 960, S90, V90 coil repair harness.Volvo 1992-98 960, S90, V90 coil repair harness.
<<<
  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



   
Volvo 1992-98 960, S90, V90 coil repair harness.<<< At left is an original Volvo 960 COIL HARNESS section I removed from a 960.  As you can see in the close-up, the coil connectors have begun deteriorating.

Volvo 1992-98 960, S90, V90 coil repair harness.<<< The connectors will deteriorate until there is almost nothing left to hold and seal the connection.

Volvo 1992-98 960, S90, V90 coil repair harness.






CUSTOMER FEEDBACK:
It took me forever to finally find time to install the ignition coil wiring harness I ordered for my 94 Volvo 960, which I did yesterday.  It fit great and I am totally pleased with the quality of the harness, especially the fact that the wire colors match the original wiring.  That made it a no brainer when splicing into the original connections.  Mine was in sad shape, broken plastic, pins starting to corrode, etc.  Yours was the perfect solution and I'm so glad you are still making parts to help keep these older Volvos on the road.  Totally pleased. Thanks.  If I could comment on your web site, I would.  T.M., Waynesboro, VA.



REPLACEMENT OPTIONS:
Until now, there very 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). 
2.  Have someone make repairs using junk yard parts or parts you might get from Volvo.
3.  Send the car to the junk yard.  This actually happens a lot.

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.


This is the new replacement Coil Repair Harness.
A new repair harness will solve this common coil connector problem
in any 960, S90 or V90 (1992-98).

Volvo 1992-98 960, S90, V90 coil repair harness.
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)

 
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Price: $165.00 each plus shipping.

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1999-2006 Volvo 6 Cylinder Coil NEW Repair Harnesses
1999-2006 Volvo with 6 Cylinders.
Why do coil harnesses need to be replaced in Volvo cars?
  As these cars age, deterioration of the coil plugs under the top coil cover on these engines is becoming 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.


Volvo 1999-2006 6 cylinder coil repair harness.
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)

 
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Price: $175.00 each plus shipping.


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OPTIONAL ITEM
VVT Connector Harness Pigtails
Available to order with coil repair 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
Single Connector Type 1 (large)

If you find a different connector on your 1999-2006 6 cylinder car, please let us know.
Wire pigtail length is about 30 inches.

Volvo 1999-2006 6 cylinder VVT (Type 1) harness.Volvo 1999-2006 6 cylinder VVT (Type 1) harness.

Price: $16.00 each plus shipping if purchased with coil repair harness ABOVE. 

$20.00 each if purchased separately BELOW.


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1999-2011 Volvo 5 Cylinder
New Replacement Coil Repair Harnesses

1999-2011 Volvo Turbo and Non-Turbo, 40, 50, 60, 70, 80 and XC90 series with 5 Cylinder Engines.

Why do coil harnesses need to be replaced in Volvo cars?
  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.



Volvo 1999-2011 5 cylinder coil repair harness.
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.
These were previously available only for 1999-2007 models with 5 cylinders.  I have recently revised the below instructions to add 2008-2011 models. The fit is correct for these newer models also, however there are wire color differences. At this time, I cannot comment on 2012 and later models.  I don't yet have access to wire diagrams for those.

FULLY DETAILED INSTRUCTIONS WITH PHOTOS:
CLICK HERE (PDF 5mb)

 
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OPTIONAL ITEMS
VVT or CVVT Connector Harness Pigtails Below
Available to order with above 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
1999-2007 TURBO models (or most likely T5 models) will usually have dual VVT sensors.
Wire pigtail length is about 30 inches.

Volvo 1999-2011 5 cylinder VVT (dual) harness.Volvo 1999-2011 5 cylinder VVT (dual) harness.Volvo 1999-2011 5 cylinder VVT (dual) harness.Volvo 1999-2011 5 cylinder VVT (dual) harness.

Price: $20.00 each plus shipping if purchased with coil repair harness ABOVE. 

$24.00 each if purchased separately BELOW.


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New Single VVT Connector with Wire Pigtail
Single Connector Type 1 (large)

1999-2007 non-turbo models 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 numbers outside these parameters may have a Single Connector (Type 2 or Type 3) further below.
Wire pigtail length is about 30 inches.

Volvo 1999-2011 5 cylinder VVT (Type 1) harness.Volvo 1999-2011 5 cylinder VVT (Type 1) harness.

Price: $16.00 each plus shipping if purchased with coil repair harness ABOVE. 

$20.00 each if purchased separately BELOW.


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

Volvo 1999-2011 5 cylinder VVT (Type 2) harness.

Price: $16.00 each plus shipping if purchased with coil repair harness ABOVE. 

$20.00 each if purchased separately BELOW.


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

Volvo 1999-2011 5 cylinder VVT (Type 3) harness.

Price: $16.00 each plus shipping if purchased with coil repair harness ABOVE. 

$20.00 each if purchased separately BELOW.


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2000-2004 Volvo 4 Cylinder (S40, V40)
New Replacement Coil Plug Repair Kits
2000-2004 Volvo S40 or V40 series Turbo and Non-Turbo with 4 Cylinders (2 coils).
Volvo 200-2004 S40 5cyl coil repair harness.Volvo 200-2004 S40 5cyl coil repair harness.
Why do coil harnesses need to be replaced in Volvo cars?
  <<< 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 Replacement Coil Plug Repair Kit

This new coil plug repair kit will solve the common coil connector problems in your S40 or V40.
Volvo 200-2004 S40 5cyl coil repair harness. Volvo 200-2004 S40 5cyl coil repair harness.
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)

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