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Repair kit wiring harness ignition coil

Volvo 900 (960), S90, V90

23.11.2021

Repair of the ignition wiring harness of the Volvo 960, S90, V90 inline six-cylinder engine.


Loosen the screws of the engine cover.


Remove the cover.


Remove the plugs from the six ignition coils.


Remove the rubber grommet behind the sixth cylinder.


Disassembled grommet.


Disconnect all plugs of the ignition coil wiring harness. One plug connection is located behind the cylinder head and is difficult to access. When all the connectors have been disconnected, you can pull the wiring harness out of it` s routing.


Carefully cut the insulation tube to expose the cables.

Please note! First compare the cable colours of the original cable harness with the colours of the new cable harness.
Six of the new cables are white.
The colour coding is done using small colour rings. The red wire with the green colour ring corresponds to the original red/green wire.

When the colours match, separate the wires with a side cutter.


Cut off the service terminal connector from the original wiring harness, as the connector will be reused.


Strip the cable of the connector.


Strip the red/white cable on the new wiring harness as well.


Twist the two stripped ends...


...and crimp them together in one of the larger (blue) crimp connectors.


This should now look like this.


Shorten the remaining cables of the replacement harness to the length of the original cables.


Strip the cable ends and apply the remaining crimp connectors.


The smaller red connectors to the white cables, the larger blue connector to the red/green cable.


Also strip the cable ends that were left in the engine compartment when the original wiring harness was cut off.


Slide the heat shrink tubing over the new wiring harness.


Connect (crimp) the new wiring harness to the cable ends in the engine compartment. Pay attention to the colours!


Pull the heat shrink tubing over the connections and shrink it.


Reinstall the new wiring harness to the original mounting points.


Attach the new connector housings. Push in the cable and fix it by pressing down the clip. Pay attention to the correct polarity!
The ignition coils are marked with (15+) and (-), the red/green marked wire must always be on (15+).

Marked ignition coils.

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  • All notes serve only as an example and do not replace the workshop instructions of the automobile manufacturers! All information is supplied without guarantee!

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