Electrical System - General Information: Other Volvo S80 I

Cable Terminals box, p/n 9814232

Contents

The table below shows which cable terminals are included in the kit, and the tool used for the different cable terminals.

Scheme 1371

Selecting a terminal removal tool

* 1 When the cavity opening has two extraction groove

Scheme 1372

* 2 When the cavity opening has one extraction groove

Scheme 1373

* 3 When the cavity opening is round

Scheme 1374

* 4 For tab terminals in receptacle housings with half-open contact side

* 5 Compartment, box in kit

Cable Terminals Kit, p/n 9814233

Contents

The table below shows which spare parts are included in the kit, and the tool included for ring cable terminals.

** For housings for 2.8 SWS cable terminals

* 5 Compartment, box in kit

Cable Terminals Kit, p/n 9814234

Contents

The table below shows which spare parts are included in the kit, and the tool included for the different cable terminals.

Selecting terminal removal tool

* 1 When the cavity opening has two extraction groove

* 2 When the cavity opening has a extraction groove

* 3 When the cavity opening is round

* 4 For tab terminals in receptacle housings with half-open contact side

* 5 Compartment, box in kit

Scheme 1375

Terminal with integrated cable designated "cable terminal", certain cases "service terminal".

Scheme 1376

Black marking = terminal's surface treatment is gold. Marking introduced running from second quarter 2008.

Due to oxidation and galvanic currents, female and male connections with the same surface treatment should be used.

Example of different surface treatments: Gold (Au), Silver (Ag), Tin (Sn)

1. Silver + Tin = Permitted
2. Tin + Gold = Not permitted
3. Silver + Gold = Permitted

Scheme 1377

The type of surface treatment on the connector can only be determined by inspection the male connector's pins with a magnifying glass.

Cable terminals, different types

The part numbers of the cable terminals are not given here. Refer to Volvo Spare Parts Catalogue for the model concerned.

Cable terminals are divided up into the following main groups

There are many different types of cable terminals intended for different purposes depending on current, mechanical stress, temperature, vibration etc.

Scheme 1378

Moisture proof cable terminals are used where there is a risk of oxidation.

1. Moisture proof cable terminals complete with cables are available both as pin and as socket fittings.

Note that these cable terminals are supplied as a complete spare part, ready-pressed and crimped with molded plastic covers on the cable.

Scheme 1379

Scheme 1380

Cable terminals intended for use with screws/bolts and available in the following variants

1. Insulated and uninsulated
2. Closed crimping connection and open crimping connection.

1. Ring cable terminals are available in sizes to fit screws/bolts from M3.5 to M16

Scheme 1381

Receptacle terminals are available in different variants

1. With locking tab and without locking tab.
2. With dimpling and without dimpling.
3. In sizes 2.8, 4.8, 6.3, 8 and 9.5

1. The most common sizes are 4.8 and 6.3

Scheme 1382

Tab terminals are available in different variants

1. With locking tab and without locking tab.
2. In sizes 2.8, 6.3 and 9.5

1. The most common sizes are 2.8 and 6.3

Scheme 1383

1. SWS designation means that a seal must be installed in the insulation wings.

1. Tab SWS is available in size 2.8

Scheme 1384

1. steel The "steel" designation means that the cable terminal tab or pin is reinforced with a steel spring.
2. SWS The "SWS" designation means that a seal must be used in the insulation wings.

1. Tab steel SWS is available in size 2.8

Scheme 1385

Timer is a socket type cable terminal used with a tab terminal. Timer terminals are found in multiple pin housings.

1. Timer terminals variants can be found with 1 or 2 locking tabs.

1. Timer are available in sizes 1.6, 2.8 and 6.3

Scheme 1386

1.6 Timer are also known as Microtimer.

2.8 Timer are also known as Minitimer.

6.3 Timer are also known as (Power)timer.

Scheme 1387

Timer is a socket type cable terminal used with a tab terminal. Timer terminals are found in multiple pin housings.

1. SWS The SWS designation means that a seal must be used on the insulation wings.

Scheme 1388

Cable terminal 0.64 is available in one variant

1. With 2 locking tabs on the upper side
2. Only 0.64 socket can be replaced. The equivalent 0.64 pin is mounted as a fixed part on components.

Scheme 1389

Scheme 1390

Scheme 1391

Pin terminals are available in a number of variants

1. Without locking tab, with 1 locking tab and with 2 locking tab.
2. In sizes 1.6, 2.1 and 3.5 (A selection of pin terminals is shown in the illustrations)

1. The most common sizes are 1.6 and 3.5

Scheme 1392

Scheme 1393

Scheme 1394

Socket terminals are available in a number of variants

1. Without locking tab, with 1 locking tab and with 2 locking tab.
2. In sizes 1.6, 2.1 and 3.5 (A selection of socket terminals is shown in the illustrations)

1. The most common sizes are 1.6 and 3.5

Scheme 1395

A terminal removal tool p/n 9814229 with a single blade type tip must be used.

This terminal removal tool is used for cable terminals with one locking tab

A 2.8 Timer

Scheme 1396

B 6.3 Receptacle terminal

Scheme 1397

There are two sizes of the cavity opening.

See illustration.

Choose a terminal removal tool with ends which match the cavity opening extraction groove.

1. The narrow ends are 1.5 mm wide.
2. The wider ends are 2.7 mm wide.

Press the cable terminal in the cavity forwards as far as it will go to free the locking tab from the cavity catch.

Insert the terminal removal tool in the groove as shown in the illustration.

Always follow the instructions in section. See When secondary locking is of the lid type which give the correct working procedure.

1. Proceed to chapter. See «New cable terminal»(ref-461674-S03260884432012040200000) «Seal SWS and plug»(ref-440496-S11228169512011121400000) . Replacing a cable terminal in order to crimp a new cable terminal.

Checking the cable

Note. Applies only to carphones with Volvo On Call.

Scheme 1398

1. Ignition off
2. Disconnect the battery negative terminal
3. Disconnect central electronic module (CEM) connector D, phone module (PHM) connector A and the supplemental restraint system module (SRS) connector
4. Ignition on
5. Connect the battery negative terminal. CAUTION: There must not be anyone inside the passenger compartment when the battery is connected. The collision cable runs from the SRS control module to the carphone module (PHM) and the central electronic module (CEM). If the cable is defective, there is a risk that the safety measures in the central electronic module (CEM) and the emergency call from the carphone module (PHM) will fail if the airbag system is activated. Checking for short-circuits to ground Check the collision sensor cable. Check for a short-circuit to ground. Measure resistance between body ground and one of the following connectors: carphone module (PHM) connector terminal A17 (#17) central electronic module (CEM) connector terminal 5D (#B5) SRS control module connector terminal 30 (#2B). The resistance between a fault free cable and body ground should be infinite. Checking for contact resistance and open-circuits Check the connectors for the control modules. Check for contact resistance. Check the collision sensor cable. Check for an open-circuit. Measure the resistance between all the connectors: carphone module (PHM) connector terminal A17 (#17) central electronic module (CEM) connector terminal 5D (#B5) SRS control module connector terminal 30 (#2B). The resistance of a fault free cable is approximately 0 ohms. Checking for short-circuits to supply voltage Check the collision sensor cable. Check for a short-circuit to voltage. Use a voltmeter to take readings between the battery positive terminal and one of the following connectors: carphone module (PHM) connector terminal A17 (#17) central electronic module (CEM) connector terminal 5D (#B5) SRS control module connector terminal 30 (#2B). Remedy as necessary. Other information To connect the breakout box to the carphone module (PHM), see «Connecting the breakout box. Carphone module»(ref-461685-S28503757612012040200000) To connect the breakout box to the central electronic module (CEM), see «Connecting the breakout box»(ref-440219-S11168147052011121400000) To connect the breakout box to the SRS module, see «Connecting the breakout box»(ref-461645-S16929971022012040200000) .

Scheme 1399

Scheme 1400

Scheme 1401

1. Ignition off
2. Connect the breakout box
3. Control module disconnected.
4. Switch off all equipment that takes power from the battery (for example, courtesy lighting, radio etc.). Check the resistance between the battery negative terminal and breakout box terminal #16 and between the battery negative terminal and breakout box terminal #46. The resistance must be 0 ohms. Check the ground terminal 1/1 (battery negative terminal) if the resistance is incorrect. Check for an open-circuit and contact resistance. Check the cable between ground terminal 31/95 (left-hand wheel arch) and brake control module terminals #16 and #46. Check for an open-circuit. Check for contact resistance.

Scheme 1402

Scheme 1403

1. Ignition off.
2. Disconnect the connector to the Engine Control Module (ECM). Checking the power supply Check fuses. Check the voltage feed to the Engine control module (ECM). Take readings between: Engine Control Module (ECM) #B1 (#C1) and system relay. Engine Control Module (ECM) #B3 (#C3) and system relay. Engine Control Module (ECM) #B5 (#C5) and system relay. Checking the ground terminal Check the ground terminal and the wiring connected to it. Check for contact resistance and oxidation. Take readings between: Engine control module (ECM) #B2 (#C2) and grounding point. Engine control module (ECM) #B4 (#C4) and grounding point. Engine control module (ECM) #B6 (#C6) and grounding point. Remedy as necessary. Other information See «Connecting the breakout box, engine control module (ECM)»(ref-461689-S12755146862012040200000) See «Signal specification, engine control module (ECM)»(ref-461690-S22335915812012040200000) See «Checking wiring and terminals»(ref-440209-S33835172972011121400000)

Was a fault detected?

1. YES OKAY: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-461676-S02001172002012040200000)

Fault-tracing information

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Connector anti-lock braking system module (ABS)

Special tools

9512630

9512631

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 1404

Disconnect the secondary lock. Use an electrician's screwdriver, as shown in the illustration.

Scheme 1405

Use tool: 9512630 and tool: 9512631 to remove the primary lock. See the illustrations.

At the same time pull the cable carefully backwards.

Connector sealed type 1

Special tools

9512631

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Dismantling

Note. The connector has no secondary lock.

Scheme 1406

Use tool: 9512631 to remove the primary lock. See the illustrations.

At the same time pull the cable carefully backwards.

Scheme 1407

Connector sealed, type 2

Special tools

9512632

9512639

9512852

9512853

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 1408

Release the catches and pull out the secondary lock. Use tool: 9512853 or an electrician's screwdriver, as shown in the illustration.

Scheme 1409

Use tool: 9512632 and 9512639 to remove the primary lock, see illustration.

At the same time pull the cable carefully backwards.

Scheme 1410

Alternatively use tool: 9512852 see illustration.

Note. Tool 9512852 can only be used for socket housings.

Connector sealed, type 3

Special tools

9512637

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 1411

Adjust the lock pins using an electrician, s screwdriver and press up the secondary lock, as shown in the illustration.

Scheme 1412

Use tool: 9512637 to press down the cable terminal locking tab. See the illustration.

At the same time pull the cable carefully backwards.

Connector type 1

Special tools

9512636

9512637

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 1413

Angle up the secondary lock (1), see illustration. Use an electrician's screwdriver.

Scheme 1414

Use tool: 9512636 and 9512637 to remove the primary lock, see illustration.

At the same time pull the cable carefully backwards.

Connector type 2

Special tools

9512632

9512633

9512639

9512852

9512853

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Connector type 3

Special tools

9512630

9512631

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 1415

Fold up the secondary lock. If necessary use an electrician's screwdriver.

Scheme 1416

Use tool: 9512630 and 9512631 to remove the primary lock, see illustration.

At the same time pull the cable carefully backwards.

Connector type 4

Special tools

9512632

9512639

9512810

9512852

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 1417

Angle the catches outwards on both sides.

Pull out the secondary lock.

Scheme 1418

Scheme 1419

Use tool: 9512810 , 9512632 and 9512639 to remove the primary lock, as graphics.

At the same time pull the cable carefully backwards.

Scheme 1420

Alternatively use tool: 9512852 , see illustration.

Note. Tool 9512852 can only be used for socket housings.

Connector type 5

Special tools

9512632

9512639

9512852

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 1421

Angle the catches outwards on both sides.

Pull out the secondary lock.

Scheme 1422

Scheme 1423

Use tool: 9512632 and 9512639 to remove the primary lock, see illustration.

At the same time pull the cable carefully backwards.

Scheme 1424

Alternatively use tool: 9512852 , see illustration.

Note. Tool 9512852 can only be used for socket housings.

Connector type 6

Special tools

9512632

9512633

9512639

9512852

9512811

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 1425

Press the secondary lock out from the cable side, for example using tool: 9512811 or an electrician's screwdriver, as shown in the illustration.

Scheme 1426

Scheme 1427

Scheme 1428

Use tool: 9512632 , 9512633 and 9512639 to remove the primary lock, as graphics.

At the same time pull the cable carefully backwards.

Alternatively use tool: 9512852 as shown in the illustration

Note. Tool 9512852 can only be used for socket housings.

Connector type 7

Special tools

9512639

9512637

9512812

9512633

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 1429

Press the secondary lock out from the cable side, for example using tool: 9512633 or an electrician's screwdriver, as shown in the illustration.

Scheme 1430

To remove the center cable terminals, use tool: 9512639 , see the illustration.

At the same time pull the cable carefully backwards.

Scheme 1431

Release the inner housing section on the socket housing: Lift the sleeve beside the catch and pull the housing section outwards.

Use tool: 9512812 or 9512637 . See the illustration.

At the same time pull the cable carefully backwards.

Explanation

Not all described parameters are implemented in the accessory electronic module (AEM). Parameters vary from system to system.

Frozen values are parameter values that are stored when a diagnostic trouble code (DTC) is stored.

Battery voltage, value

Measurement range: 8-16 V.

Normal value when the alternator is charging: 13.0-14.5 V.

Distance, value

Measurement range: 0-1048575 km.

The value indicates the total mileage of the vehicle at the time the diagnostic trouble code (DTC) was generated.

Passenger compartment temperature, value

Measurement range: -60 to 195 °C.

Outside temperature, value

Measurement range: -128 to 127.75 °C.

Engine running, status

The status displays whether the engine was running when the diagnostic trouble code (DTC) was stored.

No = the engine was not running

Yes = the engine was running

Time, value

The value displays the time that has passed since the diagnostic trouble code (DTC) was stored.

Power supply for the reverse (reversing) warning system, status

Note. Does not apply to 2004

Indicates the status of the power supply for the reverse (reversing) warning system when the diagnostic trouble code (DTC) was stored.

The status is listed at four different levels: Active, Not active, High or Low.

Sound signal for the reverse (reversing) warning system, status

Note. Does not apply to 2004

Indicates the status of the sound signal (buzzer) from the reverse (reversing) warning system to the accessory electronic module (AEM) at the time the diagnostic trouble code (DTC) was generated.

The status is listed at three different levels: Sound constantly on, Sound off or Number of milliseconds the signal sounds.

Power supply to the buzzer cable for the reverse (reversing) warning system, status

Note. Does not apply to 2004

Indicates the status of the voltage on the buzzer cable from the reverse (reversing) warning system to the accessory electronic module (AEM) at the time the diagnostic trouble code (DTC) was generated.

The status is listed at two different levels: High or Low.

Power supply to the relay for the engine block heater, status

Indicates the status of the power supply to the relay for the engine block heater when the diagnostic trouble code (DTC) was stored.

The status is listed at four different levels: Active, Not active, High or Low.

Power supply for remote start, status

Indicates the status of the power supply for the for the remote start when the diagnostic trouble code (DTC) was stored.

The status is listed at four different levels: Active, Not active, High or Low.

Voltage on the signal cable for remote start, status

Indicates the status of the voltage on the signal cable from the remote start unit to the accessory electronic module (AEM) at the time the diagnostic trouble code (DTC) was generated.

The status is listed at two different levels: High or Low.

Power supply for alarm cable P0 or P1, status

Indicates the status of the power supply to alarm cable P0 or P1 when the diagnostic trouble code (DTC) was stored.

The status is listed according to four different levels for P0 and P1 respectively: Active, Not active, High or Low.

Power supply for alarm cable S0 or S1, status

Indicates the status of the power supply to alarm cable S0 or S1 when the diagnostic trouble code (DTC) was stored.

The status is listed according to four different levels for S0 and S1 respectively: Active, Not active, High or Low.

Power supply for carphone mute, status

Indicates the status of the carphone mute signal from the accessory electronic module (AEM) at the time the diagnostic trouble code (DTC) was generated.

The status is listed at four different levels: Active, Not active, High or Low.

Voltage on the carphone mute cable, status

Indicates the status of the voltage on the carphone mute cable to the accessory electronic module (AEM) at the time the diagnostic trouble code (DTC) was generated.

The status is listed at two different levels: High or Low.

Rheostat signal, value

Indicates the percentage value of the rheostat signal from the accessory electronic module (AEM) to the radio.

The value is between 0-100%.

Speed signal, value

Indicates a frequency based on the speed and wheel circumference using the formula: frequency = speed x 12/wheel circumference. The frequency signal is used to determine the volume of the radio.

The value is between 0-512 Hz.

Power supply for aerial amplifier, status

Indicates the status of the power supply for the aerial amplifier when the diagnostic trouble code (DTC) was stored.

The status is listed at four different levels: Active, Not active, High or Low.

Opening secondary locking, Example 1

Socket type housings p/n 3523410-3, and equivalent pin housings

Scheme 1432

1. Pull back the rubber cover on the cables
2. Remove rubber gasket (socket housings only).
3. Carefully release the clips by bending them out with a small screwdriver (one clip per side).
4. Depress the catch on the front of the housing and lift the housing out of the connector cover.

Scheme 1433

Release the housing secondary locking as shown.

1. Insert a small screwdriver (approx. 3 mm blade width) as shown. Bend the secondary locking catch outward carefully and push the locking cover forwards 1.5 mm.

Scheme 1434

1. Release the pin housings from each other.

The illustration shows pin housings with the contact side up.

Scheme 1435

Open the housing section to replace terminal

Front housing section

1. The front housing section opens by carefully bending the secondary locking out and sliding the locking cover forwards 1.5 mm.

Other housing sections

1. The other housing sections open by pressing in the locking catch on the cable side and sliding the locking cover forwards 1.5 mm.

Scheme 1436

No terminal removal tool is required.

1. Extract the cable terminal from rear of the by pulling on the cable.

Scheme 1437

The cable terminal is 1.6 Pin/Pin socket.

1. Use a strip length of 3 to 4 mm and strip the cable as described in. See «Cutting and checking a cable»(ref-440496-S31972403762011121400000) and «Stripping the cable»(ref-440496-S30193642562011121400000) .
2. Use crimp tool (green) p/n «9814226»(ref-403953-S16029971462011061000000) and crimp the cable terminal as described in. See «Place the cable terminal in the tool»(ref-440496-S28064603212011121400000) .

Insert new cable terminal

Note. Note The locking cover must be in the open position protruding 1.5 mm as described in Open the housing .

1. Insert the new cable terminal in the housing from the cable side in the correct cavity. A "click" can be heard when the terminal is pushed fully home.

Scheme 1438

Secondary locking

1. Push the locking cover back to the starting position for secondary locking of the housing. A "click" indicates the lock has engaged.

Check

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

Opening secondary locking, Example 2A

Socket housings p/n 6849321-2

Crimp new cable terminal

The cable terminal is 1.6 Pin socket.

1. Use strip length 3 to 4 mm and strip the cable as described in. See «Cutting and checking a cable»(ref-440496-S31972403762011121400000) and «Stripping the cable»(ref-440496-S30193642562011121400000) .
2. Use crimp tool (green) p/n «9814226»(ref-403953-S16029971462011061000000) and crimp the cable terminal as described in. See «Place the cable terminal in the tool»(ref-440496-S28064603212011121400000) .

Insert new cable terminal in housing

Note. Note The housings secondary locking must be open, see Open socket housing .

1. Insert the new cable terminal in the correct socket housing cavity from the cable side. A "click" indicates that the catch has engaged.

Scheme 1439

Secondary locking

1. Activate secondary locking by turning both the ring sections as shown in the illustration. A "click" indicates that the secondary locking has engaged.

Check

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

Opening secondary locking, Example 2B

Pin type housing p/n 3545784-5

The cable terminal is 1.6 Pin.

1. Use strip length 3 to 4 mm and strip the cable as described in. See «Cutting and checking a cable»(ref-440496-S31972403762011121400000) and «Stripping the cable»(ref-440496-S30193642562011121400000) .
2. Use crimp tool (green) p/n «9814226»(ref-403953-S16029971462011061000000) and crimp the cable terminal as described in. See «Terminal crimping in general»(ref-440496-S28870707242011121400000) «Cable terminals - crimping core wings»(ref-440496-S40581853752011121400000) «Choice of crimp tool»(ref-440496-S38828196992011121400000) «Crimping a cable terminal»(ref-440496-S20047154402011121400000) .

Insert the new cable terminal in housing

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

1. Insert the new cable terminal in pin housing from the cable side in the correct cavity. A "click" indicates that the catch has engaged.

Scheme 1440

Secondary locking

1. Close the housing and activate secondary locking by turning both the ring sections as shown in the illustration. A "click" indicates that the secondary locking has engaged.

Check

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

Opening secondary locking, Example 3

Socket type housing p/n 3523276-8

Scheme 1441

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

Scheme 1442

Release the secondary locking catches (one on each side) as follows

1. 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. See When the cavity opening has two extraction grooves .

Crimp the cable terminal as in. See Place the cable terminal in the tool .

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 .

1. 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.

Scheme 1443

Secondary locking

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

Check

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

Opening secondary locking, Example 4

Socket type housings p/n 1362989-4, and corresponding pin housings

Scheme 1444

Hold the housing as shown and open the secondary locking as follows

1. Using a small screwdriver press the catches on the secondary locking in from the side shown in the illustration. A "click" will be heard.

When the secondary locking is pressed in the locking cover slides open and the cavities open.

Follow instructions in Cavity opening with one extraction groove .

Crimp new cable terminal as in. See Place the cable terminal in the tool .

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

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

Scheme 1445

Hold the housing as shown and close it by activating the secondary locking as follows

1. Using a small screwdriver press in the catches on the secondary locking from the opposite side. A "click" indicates that the secondary locking has engaged.