[John Sargent] If the airconditioning and heater fan are used much, all 1984-87 760s, and all 740s and 940s (not the 940SE) will eventually wear out the fuse holder for these functions. Take clips off wire. Grounded circuits occur when a bare wire is allowed to touch the vehicle's powertrain, sheet metal or frame. Remove the intake hose from the AMM to the throttle body. Owners of all vehicles manufactured with Bosch electrical systems during the period should inspect the engine wiring harness. When they do fail, the failure will be predictable, such as a bad current or ground connection, blown fuse and the like. First remove the plastic storage box (which also contains the accessory socket) above it to facilitate this. Owners who prefer to do the job themselves should set aside one or two days. If you can get enough slack in the black wire which supplies fuse 16, a red wire nut works great for spicing the new fuse holder in and keeping fuse 16 supplied with power. If they are (and they probably are) you either have a bad high/low switch (unlikely), or a bad Lamp Failure Relay. A heat gun is the best tool for applying shrink tube to a splice. Note: for intermittent driveability problems, see the section on de-oxidizing engine wiring connectors in the Performance section of the FAQ as well as brief notes on engine ground straps. Beginning in 1995, 960 cars have relays in the engine compartment and in the fuse panel shown above. Remove oil pressure wire--a push together clip. Another is that if you catch the problem soon enough no other wires will fry because of a short between two of the bad wires. I recommend you do this also, as to work around and under the intake would be treacherous. will not show this change in the color, size, and location of this relay (versus the white, rectangular, second-row position, for earlier 940s). to the tip and then wipe the solder off so that the tip is shiny. known loads. If the problem really is a ground issue, the wire may confirm the diagnosis or, when properly secured, be a permanent solution. Dealers who offer club discounts will add their standard discount to the current prices. Note that ROSIN core solder is NOT plumber's solder, which is acid core. pins and then shoved relay onto the connector body. [Quick preventative:] Watch the wires coming from the connector directly under the windshield below the driver and the oil pressure and alternator wires on the right front of the motor. Tune the car radio to a quiet (unused) AM channel. This eliminates guesswork and protects ground-sensitive electronic circuits like air bag sensors. Posted by John Adams on May 04, 2017. Replacing takes a little more time but it isn't hard to do. Install Insulated Tubing. Knock sensor wire is not replaced, just easier to work with it out of the way. They were made to do this. Enter vehicle info. There are a lot of devices on that fuse. Now you can remove the harness from the engine area and install the new. [Editor] The door harness wiring can flex and fail over time, causing intermittent door component failures (windows, locks, mirrors). There are two terminals in the relay base which connect, in parallel, Unplug the lock motors and check to make sure they operate freely. Since the flaky set are wrapped into the main harness to replace them means replace everything. The one to the right of it is the same Hella relay, used for high beam lighting. Find out now. Once the wires are removed, use a small screwdriver to raise the black plastic over the three lips on the front of the fuseholder. [Response: Abe Crombie] The electrical switch behind ignition lock is almost certainly the culprit. Seats. By merely reversing the movable contacts (either by swapping them side to side or actually rotating them around) you expose the unused contact pads and double the switch life. The heavy connections that go to large components like the actual relay may need a large soldering iron or gun, whereas the connections at smaller components, such as transistors, should be reflowed using a smaller iron, like a 25-Watt iron. Thumbs Up: 0: Headlight Relay 4109070 Malfunction I recently purchased a 2003 9-3 SE and within a week, I got the dreaded "Headlamp Failure" message on the SID. It is fuse 14 on the early 700 series, and fuse 16 on the later 740s and 940s. Bulb-Out Relay. been replaced so the relay gets good contact. 1446614-8FT for $5 USD). Left and right taillight grounds; often corroded and a cause of malfunctioning rear bulbs, On the right console between the seats: usually not a corrosion area but the strap to the transmission can corrode, Courtesy lamp ground above the left B-pillar; usually not a problem, Fuel pump and sensor ground next to sending unit on fuel tank: frequently corroded, SRS ground beneath the driver's seat next to the crash sensor. Soldering Tutorial. If no, what's the fix (another relay??). [Dick Riess] For those feeling threatened by this job, it can be done relatively easily, in my case under 4 hours of puttering slowly. [SGFM] Relays in most cars pull straight up from the relay base. If you jumper these terminals to 12+ and Your new harness has yellow bands indicating where the clamps should be. When the circuit is de-energized (as when the ignition is off) Advice: carry a used but working spare unit. I was even thinking of replacing the switch itself if that didn't work. Remove top portion of flame trap and hoses. [Jerry Casey] in my 945, all slave/3 door and hatch solenoids failed. Note that relays are not interchangeable. The alternator wire has the potential to supply a constant 12+ volts to any of the others ( which are to ground) and act as a heater wire inside the harness, getting hot enough to melt all the others. Main page; About us; Contact us; Volvo XC90 mk2 (Second Generation; 2016) – fuse box diagram. On overdrive relays, I have never had to replace a relay with holes in it, it seems to help a lot. Multiple, seemingly unrelated failures are often ground-related issues. connector and tube end seals around the base of the relay pins when I searched every forum I could … As in the ring terminal example, the integrity of these grounds is dependent on the quality of the mechanical connection. solenoids to do their job. Those pins are hard to crimp unless you have the correct crimp tool, so I just soldered 4 jumper wires on to the circuit board and used insulated spade connectors on the jumper wires to attach to the 4 supply wires. Beneath it you will see the relay tray behind the fuses. Pop the new switch in from the bottom of the carrier and you are all set. Silver Solder and a 1,200 degree iron. Remove the small cover near the door handle; be careful as it is likely to break ($6.00 at dealer). Unplug the coolant sensor by the heater hose inlet on the block. (big advantage). 2001 volvo s40 fuse box s60 wiring diagram with example unconventional capture 440 schemes headlight relay s70 xc90, image source: www.juegosdevestirnuevos.org. If you can, get the wires replaced before they cause other damage, do so as the cost will come out of your pocket. ALL the wires from the ECU do not show any signs of deterioration in any of the harnesses we have opened up. How much diagnostic time are you willing to spend testing a $0.98 light bulb that's nearing the end of its practical service life? Turn on the device you are using with the LCD display (like your calculator) and pass it down the offending wire. re-solder by heating the heavier part first and then applying new Next remove the two 25mm torx screws and gently pry up The fuse and fuse holder are simply overloaded in the basic design. See the Starting section for more information on slow battery discharge. Don't forget to look for broken conductive traces as well. B28/280: no engines were available for inspection. for visual images and instructions for wiring harness replacement and other maintenance items. I think I will keep a bad bulb or two in the future for such testing. However, some 760 Turbos use the green 1362914 relay. Unless your car has over 200,000 miles on it, the only part of the central electrical unit that will be bad is the fuse holder for fuse 16. 1986 740: I just noticed that my power windows work without the key in the ignition. When your diagnosis says that neither of those two things is happening, it's time to go hunting for that bad ground connection! If everything Due to the fault, it seems Use a professional DVOM with a min/max voltage feature and alarm to test intermittent failures. Its "natural" look is orange and semi-transparent. petrol), mass air flow sensor (V8), glow plugs (diesel). I shopped all over and I purchased it from NILS SEFELDT Volvo in Houston Texas (281) 721-1600 (800) 468-0041 for $230.22 and the gasket for $11.70. Do not interchange the two, as dielectric grease is an insulator, while oxidation inhibitor is a conductor. Power Door Lock Failure. Suspecting a short to ground fault within the circuit, I have examined the wiring and do not visually see any bare wire. After that it's either try a new relay or start tracing with a multimeter. The supply wire for fuse 16 also supplies fuses 14 and 15 on this car. You can remove the old solder with a sucker or copper braid and Next morning it was hard as rock and conductive! Everything about cars Skip to content. The main purpose of the grease is to seal the terminals against oxidation which creates a high resistance barrier and moisture and dirt which can result in shorts and ground paths. Fuses – engine compartment Volvo XC60 – fuse box – engine … Relay Tray Removal and Replacement. Be careful not "to drag" solder between pins. Volvo XC90 … I had the same problem and after replacing the relay, I replaced the plastic base. An open circuit, obviously, is a broken or disconnected wire. Picture References. All automotive fuse box diagrams in one place. Heat, time and vibration had taken their toll. It actually works better too (better switches). [Bob Kraushaar] If a relay/fuse is not firmly set in its socket, a poor contact can result, which results in overheating and melting plastic. Connect the +ve lead to the red wire in the open connector (pin 5). Easy to apply & no waste, but expensive. Note that Volvo released an improved relay, which has silver base terminals, to solve this problem. If the car's existing relay has copper-colored terminals, replace it with the newer relay. 740/940: Behind the switch cluster in the recessed area where the inner door lever lives there is as plastic screw. In the same sense, lab scopes are particularly useful to find loose ground connections. You can obviously tell by part number. The plastic headlight lenses of my 2004 Volvo Xc90 have become cloudy and appear to prematurely aging. Since a loose or corroded fuse connector may also cause many intermittent circuit failures, thoroughly inspect and clean the fuse circuits before proceeding with your diagnosis. Print this page; Share this page; Kyle Steven OHare … If you ever get this problem. Install the relay. Volvo XC90 mk2 (Second Generation; 2016) – fuse box diagram. In other unlikely cases, I've found an instrument cluster fuse that also supplies field current to the alternator. Had it replaced by the dealer thinking insurance only to find that insurance refuses to cover this problems in Volvo's. After you perform this test on each fuse, check unfused circuits such as the alternator or wiring harness. This single hot wire fed the blower, wipers and the SRS system fuses! Year of production: 2011. While identifying ground-related problems is not necessarily easy, there are some scenarios that should automatically raise a red flag. failure is one of the joints easily accessed at the top of the unit once Problems with the 740 fuel pump and headlight relays are well documented. It can go a long way in preventing oxidation. Connections that look terrible may actually be okay, and vice versa. Owners who have replaced wiring harnesses of B23 and B280 engines may wish to offer advice on other maintenance that should be performed at the same time, as well as other parts (besides the wiring harness) that may be required. Its so $$$ that it isn't used often. Clicking this will make more experts see the question and we will remind you when it gets answered. It is very difficult to find copper ones. Disconnect wires and attatch to the new switch. Now start to remove the old harness toward the engine and start to plug in new stuff. [Editor] For information about how to remove oxidation or corrosion from engine and chassis electrical connectors due to age, humidity, or corrosive environment, see the FAQ section in Engine: Performance. CAUTION: DO NOT do this to any SRS/Airbag/Seatbelt connectors: these are all gold-plated and do not oxidize. You must continue to supply power to fuse 16, as fuses 14 and 15 are fed from the supply side of fuse 16. Do these parts fit your vehicle? Message came up: "bulb failure low beam. Using Dielectric or Conductive Grease to Protect Connectors and Grounds. [Response: John Sargent] Are your low beam fuses okay? could be heard as 'clicking' at the relay, and this fried the General lighting, ceiling (RCM) Upper electronic module (UEM). The sheet-metal screw could back out as the body flexes during use and thermal cycling. This also creates a line-on-line condition that forces the strands against each other and the terminal surfaces and minimizes contamination. If it senses a bulb failure, it illuminates the instrument panel warning lamp. $149.99. then you remove fuses one at a time until the current flow drops to [Response:] This is a good question and one that I have received several times. Beginning in 1995, 960 cars have relays in the engine compartment and in the fuse panel shown above. The four switches in the driver door pod are all the same and will (normally) have pins 3 and 5 internally jumpered. 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