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.
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:

  • 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.