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(part story, part technical - I hope you at least get a laugh out of it)
I guess you really haven't arrived as a DIY owner of an older 240 until you have experienced wiring harness problems. Today it was my turn. I wonder if I caused the difficulty I'm now experiencing.
It started when I saw what was purported to be a newer replacement wiring harness for my car on eBay. There was a close up picture of the number to confirm that it was indeed the correct item. I got to thinking that I had never checked the number on the existing harness in my car. On the one hand, I always just figured it was original, and therefore undesirable, because some previous owner had run a new temp gauge wire. On the other hand, in three years of ownership I've never had any of the typical harness rot symptoms that I have seen described here. I figured it was only a matter of time though so I thought I'd have a look. I know where the number is on the replacement harnesses and I seem to recall that it's in a different location on the originals so I tried to see if the tube bearing said number was on the thinner red wire that goes to the alternator from the #30 terminal on the solenoid. I couldn't tell right off so I used a small mirror and a flashlight. I still couldn't see for sure. This is where I started getting stupid. I decided to remove the battery cable and alternator wire. I guess I was in parts identification mode and not actual repair mode because I didn't disconnect the battery ground (dumbsh*t). I got both wires off with no apparent problem and could now clearly see that there was no number at that location. It was only when putting the alternator wire and battery cable back on that I was reminded of the ground cable. This came in the form of a slight electrical shock to my right elbow which was resting on the fuel filter bracket. I cursed my own carelessness and immediatley removed the battery ground. After snugging up the nut on the solenoid I went to reconnect the ground and was surprised to hear the fuel pumps start running. I took the clamp off of the battery post and then just touched the two together briefly. I could hear what I believe to be the fuel pump relay clicking. I tried it again and the fuel pumps ran. I did this a couple of times more, just touching the clamp to the post very briefly and I would get the click or the pump noise or both. So I backed the nut off of the solenoid terminal. With that nut just sort of finger tight I could put the clamp on the post and everything was seemingly normal. But now the nut was not secure and would possibly work it's way off in regular use. So I snugged it down again and as soon as I connected the battery ground the pumps started working again. I thought perhaps that I had energized the solenoid when I shorted the circuit through my elbow but that doesn't make much sense because I didn't hear it engage and the starter motor had not turned during all of this. Still I had this idea in my mind that the pinion was hung up and current was being provided to systems when it shouldn't be so I put the car in reverse and rocked it forward and backward hoping that would dislodge it. The pumps still wanted to run. I decided to get even more stupid. With the nut backed off to where the pumps didn't run and the battery grounded I turned the key in the ignition. Of course I was too lazy to walk around to the coil and remove the wire from the #15 connection. Hey, I was just going to bump the supposedly hung up pinion for a moment thus dislodging it, right? Real genius at work. Of course the car started and ran. It ran so well that it wouldn't stop. Even with the ignition off and the key removed. And, of course, all the idiot lights were on and fully bright. Oh, and did I mention I was working in the garage with the door closed (DUMBSH*T)? So here I am in this gas chamber wondering if I'm doing serious damage to the electrical system but at least finally having the presence of mind to pull the coil wire.
After opening the garage door and airing the place out I decided to quit for the day.
So what the hell was that all about? I've had the starter off of the car and put it back on before this. I don't know why tightening the nut on the solenoid in a completely normal fashion would cause this sort of behavior or why backing it off would cause it to stop. Could I have started the problem when I got shocked? WTF did I do to bring this about? Or was it just coincidentally the old harness' time to pack it in?
Anyway, I successfully bid on and won the replacement harness. I think I may need it. Won a couple of other non-Volvo items that I really wanted too. At least it was a good day for me on eBay.
Now I am going to retire for the evening. I'll check for comments in the A.M.
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'80 DL 2 dr
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