Dave's Volvo Page - Volvo Wiring Harnesses 960 and S90

UPDATED: September 1, 2022 CONTACT VIEW CART

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960 (and S90/V90) Coil Repair Harnesses (6 cyl 1992-98)	5 Cylinder (1999-2011) Coil Repair Harnesses
960 FULL Engine Wire Harnesses
4 Cylinder (2000-2004) S40, V40 Coil Repair Harnesses	6 Cylinder (1999-2006) Coil Repair Harnesses
Main Volvo Harness Page	Shipping Info

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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.

<<< 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 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.

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).

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.

FULLY DETAILED INSTRUCTIONS WITH PHOTOS:
CLICK HERE (PDF 360 kb)

IN STOCK
If this item becomes out of stock, manufacturing lead time will be about 3-4 weeks.
Price: $165.00 each plus shipping.

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Separate Shipping for Harnesses Below
Use ONLY if shipping needs to be added separately (multiple harnesses, etc).
Shipping cost is the same for one or multiple items.

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Questions or more info: CONTACT

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 4.5mb)

IN STOCK
If this item becomes out of stock, it may still be ordered. Manufacturing lead time will be about 3-4 weeks.
Price: $175.00 each plus shipping.

ORDER HERE
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Separate Shipping for Harnesses Below
Use ONLY if shipping needs to be added separately (multiple harnesses, etc).
Shipping cost is the same for one or multiple items.

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Questions or more info: CONTACT

OPTIONAL ITEM

VVT Connector Harness Pigtails
Available to order with coil repair harness purchase.
Beginning about 2003, 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 Single 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.

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. This kit includes butt splices and heat-shrink tubing.
New original Volvo connectors are used in this harness.

NOTE ABOUT FITMENT YEAR RANGE
These repair harnesses were originally designed to fit 1999-2007 models with 5 cylinders. They will also fit models through the 2011 model year. The fit is the same, however there are some wire color differences. So fitting to a 2008 to 2011 model requires matching up some wire colors.
The below INSTALLATION GUIDE will explain the installation in detail.

At this time, I cannot comment on 2012 and later models. I have not yet located sufficient wiring diagrams for 2012 or later models.

SPECIAL INFO: FITTING THIS REPAIR HARNESS TO 2004 to 2007 S60R or V70R
The coils in the R models were slightly different and used a slightly different connector. The difference is small and it is a very simple task to modify the connectors supplied with this harness to correctly fit. I have included instructions in the below GUIDE. Please email me if you have questions.

FULLY DETAILED INSTRUCTIONS 12 PAGES:
CLICK HERE (PDF 1.5mb)

IN STOCK
If this item becomes out of stock, manufacturing lead time will be about 3-4 weeks.
Price: $175.00 each plus shipping.

ORDER HERE
Order Quantity:
Options #1 and #2 below are not required. They're explained further below if you have questions.
Option #1: Option #2:
Select Shipping:

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Separate Shipping for Harnesses
Use ONLY if shipping needs to be added separately (multiple harnesses, etc).
Shipping cost will be the same for one item or multiple items.

Separate Shipping:

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Questions or more info: CONTACTs6

.
OPTIONAL ITEMS

VVT or CVVT Connector Harness Pigtails Below
Available to order with above coil harness purchase.
Beginning about 2003, some models will have Variable Valve Timing (VVT) or Continuous Variable Valve Timing (CVVT). There are electric solenoids mounted under the coil cover and each solenoid will have a connector. Some models will have only one solenoid 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. In cases where dual VVT plugs are present, the plugs different so they cannot be plugged in to the wrong location. You may re-use your old VVT or CVVT connectors and the wire if you prefer, but you will need to remove the wires from your old coil harness bundle.

New Dual VVT Connectors with Wire Pigtails
1999-2007 TURBO models (or most likely T5 models) will usually have dual VVT sensors. The 2004-07 S60R and V70R came with dual VVT sensors.

Wire pigtail length is about 30 inches.

Volvo 1999-2011 5 cylinder dual VVT harness.

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

$24.00 each if purchased separately BELOW.

IN STOCK

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bos10e

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

Some NON-TURBO models will 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.

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

$20.00 each if purchased separately BELOW.

ORDER HERE
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New Single VVT Connector with Wire Pigtail
Single Connector Type 2 (small)

Wire pigtail length is about 30 inches.

Finding this one seems to be uncommon, but it does turn up once in a while.

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.

ORDER HERE
Order Quantity: Option:
Select Shipping Option:

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New Single VVT Connector with Wire Pigtail
Single Connector Type 3 (small)

Wire pigtail length is about 30 inches.

Finding this one seems to be uncommon, but it does turn up once in a while.

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.

ORDER HERE
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Select Shipping Option:

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bos8e

Cam Sensor Connector with Wire Pigtail
For Volvo PN 30713370 Cam Sensor
Wire pigtail length is about 18 inches.
This connector fits the below Cam Sensors. If equipped, there will normally be 2 per car.
The Cam Sensor pictured below is Volvo PN 30713370. It is found on a number of 5 cylinders up to 2014.

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

$20.00 each plus shipping 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 2000-2004 S40 5cyl coil repair harness.

Why do coil harnesses need to be repaired or 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 common coil connector problems.
Early 4-cylinder S40 or V40 with TWO coils. Each coil serves two cylinders.

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 here).

INSTALLATION GUIDE (750kb PDF) Click Here

IN STOCK
Price: $30.00 each plus shipping.

View Cart or Check Out.

Separate Shipping for Harnesses Below
Use ONLY if shipping needs to be added separately (multiple harnesses, etc).
Shipping cost is the same for one or multiple items.

Separate Shipping:

View Cart or Check Out.

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

Wire pigtail length is about 30 inches.

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

$20.00 each if purchased separately BELOW.

View Cart or Check Out.

Separate shipping may be added here if needed.
USA Shipping for any 4, 5 or 6 cyl Coil Repair Harness
STEP #1: Select your purchase above and click "Add to Cart."
STEP #2: Select Shipping for this item and click "Add to Cart"
USA Shipping:
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USA SHIPPING NOTES: Priority Mail USA is usually 2 to 3 day shipping.
Priority Mail EXPRESS is ONE DAY in most cases.
USPS delivery times can be calculated here: http://postcalc.usps.com/ServiceCommitments.aspx (use "From Zip Code": 75078)

Separate shipping may be added here if needed.
INTERNATIONAL Shipping for any 4, 5 or 6 cyl Coil Repair Harness
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