Hi Kevin,

I just did this with my '87 240. I could see bad insulation at the usual spots: the ends of the wires on the right side of the engine going to the alternator and the oil pressure switch, and the ends of several of the wires at the gray box on the firewall.

Once I replaced the harness, I cut open the old one to see how bad it was, and I found that all of the flaking insulation was within a few inches of the ends on these wires--all the wiring deeper inside the harness looked fine.

So--about 99% of my harness was actually OK, and I could have just spliced the ends. Not sure if this helps, but it might save you some $$ to go this approach if your car is the same. (Mine had 400K miles, so it had had a lot of heat on the wires).

DS

PS: Ironically, my harness (the FI harness) actually wasn't causing the problem--the problem (bad wet weather starting) was actually in the smaller ignition harness. The visual cue here was bad insulation near the ends of the wires on the two-prong oval connector near the coil. You might want to look
at that too.

Hit the Pick Ur parts. Scored one for my 86 a couple of weeks back for $29. Look inside at the Computer for a big Volvo sticker on the harness. That is a replacement harness. The factory one says Bosch one the ones I looked at. Did look for over a year before found one for my 86, but worth a shot. Try Dave, and check EBAY.

Number and photograph it all if you pull one. Seen them online from $150, and you can get one from dealership for only $800.00 They don't call them stealerships for nothin.

Good Luck,

PT

Go buy some wire and do it yourself..
--
Max..1989 244 DL 5 Spd., V15 Phase II Cam Bilstein HD, Turbo Swaybars, Poly Bushings all round, Turbo Wheels, Black leather interior, Electric mirrors, LED dash and gauge lights and now NEW ECODES with the turn signals, 1992 black 244 next project

Try davebarton.com to see all that he offers.

Good luck.
--
'86 sedan with 360K miles with original engine and automatic transmission

Do search for Dave Barton, his website. Full instructions and reasonable pricing. Sometimes you can find them on Ebay.