Hi,

I'm in the process of some major work on my son's car (trans swap, etc.) and have pretty much decided to replace the engine wiring harness while I have things apart (insulation is rotten near all of the major connectors, have already repaired it more than once). Any recommendations on the best place to get a replacement harness? Also, are the replacements made with "biodegradable" insulation or are they made with the newer, more robust materials?

Any advice, including BTDTs, would be greatly appreciated.

Regards,

Steve A-

In a search for Wiring Harnesses, I would suggest Dave Barton, or your local parts yard. I've scoped out all of the local 'slow-moving' yards (and have maps drawn with vehicle locations, Vin numbers, and accessories listed). After finding none there, I made it a point to visit the 'high-turnover' yards every 6 weeks or so. (these are the yards where the cars are only out for about a month to 3 months before being crushed.)

Just last month, one turned up. There was an '86 that had the harness I was looking for (and lots of new relays too). Volvo replacement harnesses can be identified by a Blue & White Volvo tag with black part numbers. The tag will probably be located at the computer harness connector end (mine was). If you remove the passenger side kickpanel to expose the computer, you should see the Blue and White Volvo tag wrapped around the harness bundle between the computer and the fuel pump relay.

With painstaking care, I removed the harness from the car, along with the cruise control. :) I noticed that the Fuel Pressure Regulator was new also but didn't have time to pull it since the yard was closing. I returned for the FPR 2 weeks later and the car had been crushed... Oh well. It's been replaced with an '83 yellow 242.

All told, I paid the following:
$15 Wiring harness.
$8 for 2 handfulls of relays.
$30 for a complete cruise control system.
Free - replacement thermal switch for my seat heater.

If you can't find a good harness, I would trust Dave Barton. While I've never ordered from him, I've checked his website and read his posts here on the Brickboard. He seems to be a very competent fellow who knows what he's doing.

God bless,
Fitz Fitzgerald.

P.S. I plan to relocate the 'under-the-engine' section of the harness to the inside wall of the passenger fender. The black harness jacket was already cracking on the 18 inch section that wrapped around under the oil pan and alternator (and this is the replacement harness). -yes, the part number on my harness is for the new one, #3515364.
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'87 Blue 245, NA 214K

You are saying that the insulation is cracking on your "new and improved" harness as well? Crap, I was going to "roll my own" harness until I found a low mileage "new and improved" at a reasonable price. Had I known this I would definately have made my own harness and re-routed some wiring as you plan on doing.

Justin B.
83 Turbo

I have seen new wiring harnesses pass through on eBay for reasonable prices recently. Just make sure they are Volvo NOS or a reputable replacement. The key to a good wiring harness is the fine-braided wire that is more pliable than ordinary THNN wire and very flexible insulation. I also need to do this same job on my 86, but have other issues I am working out (like the in-tank pump laying like an abandoned cucumber on my hood right now) and rear bushings.

Lance (in eastern Arkansas where Bricks are Bricks and Bimmers are nervous)

http://www.linkline.com/personal/dbarton/WireHarnesses.html
'
check out this site. I purchased a used harness from Dave for my '82. I was a little skeptical at first, but his harnesses are the updated versions. ie, non-degrading variety. His instructions and digrams are super helpful and you simply cant beat the price. ~$150.00.


Matt

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'82 DL - 158k, '93 945 - 108k