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How do I repair this wiring harness? (S60)

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive "P2" platform cars.

2001 - 2007 V70
2004 - 2007 V70 R
2001 - 2007 XC-70
2001 - 2009 S60
2003 - 2007 S60 R

gasparov12
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Year and Model: 2007 Volvo S60 2.5T
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gasparov12

How do I repair this wiring harness? (S60)

Post by gasparov12 » Thu Jul 18, 2019 8:06 pm

Hey all,

I have a 2007 Volvo S60 with a wiring harness that's seen better days.


I have an ad posted for a replacement but I'd rather try to fix it the cheapest way possible so I can get up and running again. It doesn't have to last forver.
Here are the issues:



I have a lot of ideas for fixing it but I don't know where to start. Can I just use tape on the areas away from the coil connectors? What do I do about the wires that are degraded immediately outside of the coil connectors?

Also (not pictured) I cut the 5 white and green wires rather than the 1 bigger composite wire that they all join to when I got the piece out from the engine bay. This was a rookie mistake. Anyway would it be easier to solder it back into the car, or use butt connectors?

Thank you in advance for any advice!



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MoVolvos
Posts: 1792
Joined: Sun Jan 15, 2012 6:47 pm
Year and Model: 03S80T6~08C30T5
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MoVolvos

Re: How do I repair this wiring harness? (S60)

Post by MoVolvos » Thu Jul 18, 2019 8:33 pm

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Wiring Loom / Harness - High Temp
https://www.amazon.com/225FWY-Conduit-P ... way&sr=8-6

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03 S80 T6 - I've recently used the tape to clean up the wiring for the H7 headlight wires. Like yours the plastic had crumpled and are bare.

You can use the tape on the outside of the Loom / Harness to keep the wiring in. Just a few wraps every 6 inches or where there is a bend or at the Y.

However, it was mostly used in the center console to quiet squeaking plastic. Removed the entire center console and taped everything so it does not squeak anymore.

Tesa 51608, 25m x 19mm adhesive wiring cloth tape original ISOBAND 3 pcs pack
https://www.amazon.com/gp/product/B00XP ... UTF8&psc=1

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If you can remove the wires from the plugs it is much better than the tape above. This has a glue in the center to hold the wiring tightly together.

270pcs 3:1 Dual Wall Adhesive Heat Shrink Tubing Kit, 5 Sizes (Diameter): 3/8, 1/4, 3/16, 1/8, 3/32 inch, Premium Wire Cable Sleeve Tube Assortment with Storage Case for DIY by MILAPEAK (Black & Red)
https://www.amazon.com/gp/product/B0771 ... UTF8&psc=1


Blessings,

BKM

1998 S70 T5 - Donated
2003 S80 T6
2003 GS300
2003 Odyssey
2008 C30 T5
2019 Atlas SE 4 Motion

User avatar
MoVolvos
Posts: 1792
Joined: Sun Jan 15, 2012 6:47 pm
Year and Model: 03S80T6~08C30T5
Location: NC
Has thanked: 14 times
Been thanked: 32 times
United States of America
MoVolvos

Re: How do I repair this wiring harness? (S60)

Post by MoVolvos » Thu Jul 18, 2019 8:37 pm

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Check out the wiring harness pictures. Click Customer Reviews.
https://www.amazon.com/gp/product/B00XP ... merReviews


Blessings,

BKM

1998 S70 T5 - Donated
2003 S80 T6
2003 GS300
2003 Odyssey
2008 C30 T5
2019 Atlas SE 4 Motion

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