So you may be on the right track by running the Harness differently.

This could be, but I remain skeptical. The engineers who designed the harness and its path were not only good electrical engineers, but adept mechanical designers as well.

One of the common pieces of 240 advice given on this board is to re-route the alternator and oil pressure wires around the engine bay to avoid what is perceived as a vulnerable area under the front crank. Adding two new flexing sections to the large alternator B+ wire is not extending longevity or improving safety. Notice that every wire bridging movable parts in a Volvo 240 is specially designed for flexibility, although we all know how that silicone insulation held up to age, heat, and pollution.
--
Art Benstein near Baltimore

A backward poet writes inverse.