1987 Deteriorated Wiring Harness Advice
 

Help....

I just picked up a very clean, but non running 1987 wagon with only 98,000 miles, which I believe to be accurate given the Carfax history, that the owner said had "wiring issues". I am aware of the insulation issues with this year and the harness shows evidence of the insulation failing in several places.

What course to take?

I am thinking a new engine and ignition harness from Dave's Volvo as well as a few assorted female pigtails to fix the directional connectors and the other failed wire by the coil. Cost, $592.00. While not inexpensive, I know everything will be new.
https://www.240turbo.com/volvoharnesses.html

My other thought is also sending off the ignition module to Programa in Florida to be rebuilt. I have used them in the past for repair of Mercedes HVAC modules with great success.
https://www.programainc.com/item_lis...&idcategory=40

Any advice?
https://cimg1.ibsrv.net/gimg/volvofo...457baa2078.jpg
https://cimg2.ibsrv.net/gimg/volvofo...0c5d802ef2.jpg
https://cimg5.ibsrv.net/gimg/volvofo...ab34e62748.jpg

those 'Chrysler' ignition modules on the 85(?)-88 240's are pretty reliable, I've not heard of any of them failing. the harness plug that goes into it is a weak spot, always pull it straight out, don't rock it, and use quite a bit of dialectric grease when plugging it back in.

re: biodegradable wiring, Volvo 'fixed' this mid year in 87, our late-87 had perfectly good original wiring at 500K miles.

https://cimg8.ibsrv.net/gimg/volvofo...1c42024dcc.jpg
https://cimg3.ibsrv.net/gimg/volvofo...3c42b602fd.jpg
New wiring harnesses and Programa rebuild Ignition ECU arrived. The wiring harness is top notch in quality. While not inexpensive it is nice seeing something so well made when you pay good money. Now the fun of removing the old harness and replacing it with the new begins.

use a lot of dielectric grease on that ICU connector and always insert it straight in without rocking. minimize the number of insert/removals, ideally just insert once after installing the whole rest of the harness, and leave it alone forever.

This connector really must be a common issue as Programa mentioned installing pin sleeves.

Dialectic grease already purchased. I did notice there was a lot of it, though pretty waxy, when I removed the old one.

the pin sleeves, on specific pins only, was a volvo engineering change (EC) circa 1986, our 87 240 came with it installed already, I believe it was only used on the low level signal pins, like for the hall sensor.