Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSVOLVO2001S40 L4-1.9L TURBO VIN 29 B4204T3REPAIR AND DIAGNOSISSERVICE AND REPAIRCABLESEXAMPLES OF CABLE TERMINALSEXAMPLE 3
2001 Volvo S40 L4-1.9L Turbo VIN 29 B4204T3
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.
Crimp new cable terminal
Crimp the cable terminal as in 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 (ND2).
- 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.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.