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 MANUALSVOLVO2002S80 T6 EXECUTIVE L6-2.9L TURBO VIN 91 B6294TREPAIR AND DIAGNOSISPOWERTRAIN MANAGEMENTCOMPUTERS AND CONTROL SYSTEMSENGINE CONTROL MODULEDIAGRAMSDIAGNOSTIC AIDSHOUSING WITH HALF-OPEN CONTACT SIDE
2002 Volvo S80 T6 Executive L6-2.9L Turbo VIN 91 B6294T
Housing With Half-Open Contact Side
2002 Volvo S80 T6 Executive L6-2.9L Turbo VIN 91 B6294TSECTION Housing With Half-Open Contact Side
Housing with half-open contact side
(When the cable terminals are partly exposed with the locking tabs visible in the cavities)
Housings of this type have partly exposed cable terminals on the contact side with the locking tabs visible in the cavities.
Usually this type only includes tab cable terminals with one locking tab.
Illustrated are:
A 2.8 Tab sws
B 6.3 Tab (also in sizes 2.8 and 9.5)
Use terminal removal tool p/n 951 2644 Repair kit 1 951 2644 Repair Kit 1.
The illustration below shows a housing with tabs. To extract pin cable terminals read the instructions at Housings with round cavity opening Housings With Round Cavity Opening.
Choose a terminal removal tool with an end that matches the cavity opening.
- The narrow ended tool is 1.5 mm wide.
- The wider end is 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 illustrated.
Always follow the instructions in Using terminal removal tools Using Terminal Removal Tools which give the correct working procedure.
- Proceed to chapter New cable terminal New Cable Terminal Seal sws and plug . Replacing a cable terminal in order to crimp a new cable terminal.
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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.