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1)Get spools of various colors and try to match the Volvo colors as closely as you can. Get new female connectors.
2)Solder your connections and use heat-shrink tubing on the soldered joints.
3) Remove the intake manifold to give you more room for your hands. Replace with a new gasket. (and do the flame trap while it's sitting *right there out in the open*!)
4) Bag the under-the-crankshaft location for the harness. It's far preferable to come out to the fenders and up and across the firewall. I only left the big fat wire from the alternator to the starter to pass under the crankshaft pulley.
5) Wrap your new harness in the split loom sheathing. It keeps your new wires neat and clean.
6) Before you start disconnecting the old harness, wrap a masking tape label on each wire near its connection indicating its function or connection. That way you won't get lost in a rat's nest of wires.
7) The old plastic sheathing will probably be rock hard. I ended up needing to break off pieces -- it just wouldn't cut.
Give yourself one busy day or, preferably, two relaxed days so you can enjoy yourself as you do the job.
Rob
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