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Wiring harness update.

In response to my requests for Volvo to make some adjustments to the prices of the 240 wiring harnesses for those years affected by the insulation rot problem, they have dropped their prices some. Some parts received a greater reduction than others, although, in general I am not satisfied that Volvo has done enough in this area given the high cost of repairs. Check with your local dealers for current prices.

Note that almost every year/model has a different part number for the wiring harness and that they are not interchangeable.

WARNING!!!! On two harnesses for K-Jetronic 240s that I received in the past week, the leads for the plug for the Control Pressure Regulator were REVERSED!! The symptom is that when plugged in and the car is started, the main fuel pump fuse (#7) blows immediately. It took several hours of troubleshooting to locate the problem. The repair was simple, though extremely awkward to accomplish after the harness is in place. You must peel back the rubber boot on the connector, use a small tool to release the female terminals inside the connector and slide them out, reverse, and reinsert them. The wires are blue and black. If these are connected wrong, you short the blue wire directly to ground, and the blue wire is connected to the fuel pump relay which is fed from fuse 7. There was no paper or label on the harness that these leads were reversed. I found the problem by reading the box for a new control pressure regulator - there was a warning that improper hookup of the leads would cause a fuse to blow!!

Has anyone seen a TSB referring to this problem??