Example 3

2001 Volvo S40 L4-1.9L Turbo VIN 29 B4204T3SECTION Example 3





Example 3

Socket type housing p/n 3523276-8

Replacement of cable terminals

Remove the connector cover




- Pull the rubber sleeve back on the cables.
- Keep both catches pressed in (one on each side) and pull the connector cover up.
- Remove the connector cover from the housing.

Open the housing




Release the secondary locking catches (one on each side) as follows:
- Insert a narrow screwdriver blade as shown. Carefully bend back the catch at the edge and push the secondary locking slightly forwards (approx. 1 mm).

Extract the cable terminal
Follow the instructions in When the cavity opening has two extraction grooves When the Cavity Opening Has Two Extraction Grooves.

Crimp new cable terminal




Crimp the cable terminal as in Crimping a cable terminal Crimping A Cable Terminal.
Do not forget to install a new seal on the cable.

Insert the new cable terminal in the housing

Note! The housing secondary locking must be slightly open as in Open the housing.

- Insert the new cable terminal in the housing from the cable side checking that it is in the correct cavity. A "click" indicates the catch has engaged.

Close the housing





Secondary locking
- Press the secondary locking catches (one on each side) slightly to their original position.

Check
- Carefully pull on the cables to check the terminal is firmly attached.

Reassemble the connector




- Replace the connector cover by depressing the locking catches (one on each side).
Check that the catches have engaged properly.
- Push rubber seal into place.

RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.