Modified Cooling Of Control Module Box (GROUP 37, NO. 109)
Reference number: GROUP 37, NO. 109
MODIFIED COOLING OF CONTROL MODULE BOX
TECHNICAL SERVICE BULLETIN
MODIFIED COOLING OF CONTROL MODULE BOX
Model(s): 1994-on Volvo 850
Group: 37 - Wiring
Bulletin No.: 109
Date: September 1993
REFERENCE
TP 31875/1 (ENGLISH); 5/92; LIGHTING, INSTRUMENTS, AND OTHER ELECTRICAL COMPONENTS
MODIFIED COOLING OF CONTROL MODULE BOX
From M/Y 1994, the control module box and air cooling of the control module box have been modified in order to improve cooling.
Cooling air to the control module box is taken from the climate unit, after the fan and evaporator via an opening in the firewall. An insulated air duct distributes cooling air to the control module box. Cooling air is exhausted, as before, through an air duct connected to the fan casing.
The control module box has been adapted for modified air cooling. The control module box consists of three parts, a cover, intermediate section and lower section. There is a connecting sleeve at the back of the control module box for connecting the cooling air duct. This is mounted in a guide channel between the lower and intermediate control module box sections. The various sections of the control module box are held together with metal clips.
| Contents | Operation |
| Replacing control module box | A1- A9 |
| Replacing control module connector | B1- B5 |
REPLACING CONTROL MODULE BOX
REMOVAL
A1
Disconnect battery.
Remove:
- front air duct to the control module box.
- windshield washer reservoir filler pipe.
- undo expansion tank, pull upwards.
- undo diagnostic unit. See Fig 1 .
A2
Remove:
- control module box cover, pry off the metal clips (2) with a screwdriver. See Fig 2 .
- control modules from the control module box.
- front mounting bolt.
A3
Remove:
- intermediate control module box section, pry off metal clips (3) with a screwdriver. See Fig 3 .
- connecting sleeve to the control module box air intake.
- lift up the control module mounting together with the wiring conduit by carefully prying away the sides of the bottom section of the box.
A4
- Disconnect the connector at the bottom of the control module box.
Remove:
- the wiring clamp screws on the side of the control module box.
See Fig 4 .
- rear mounting bolt.
- the wiring clamp at the side of the control module box.
- pull up the wiring at the side of the control module box unhooking it from the side of the control module box.
- the lower section of the control module box, pull backwards to free it from the metal flap on the car body at the front of the control module box. See Fig 5 .
INSTALLATION
A5
- Reinstall lower section of the control module box. See Fig 6 .
Install:
- the wiring clamp at the side of the control module box.
- the lower control module box section, fit it into the flap on the car body at the front. See Fig 6 .
- rear mounting bolt.
A6
Install:
- Plug together connector at the bottom of the control module box and fit into holder.
- wiring at the side of the control module box.
- the wiring clamp screws at the side of the control module box.
See Fig 4 .
A7
Install:
- control module mounting, ensure that clips engage.
- wiring conduit, fit into the channel in the control module box.
- the control module box air intake connector sleeve. See Fig 7 .
- the intermediate control module box section.
Check that the intermediate and lower control module box sections fit tightly and that the clips engage properly.
A8
Install:
- front mounting bolt.
- control modules.
- the control module box cover, ensure that clips engage properly.
See Fig 8 .
A9
Install:
- diagnostic unit.
- windshield washer reservoir filler pipe.
- front air duct to the control module box. See Fig 1 .
- expansion tank.
Reconnect battery.
- Reset radio code and clock.
REPLACING CONTROL MODULE CONNECTOR OR TERMINAL IN CONNECTOR
REMOVAL
Take apart control module box in accordance with A1-A4.
B1
- Remove the rubber mat on the mounting.
- Undo the mounting, bend the two halves upwards slightly to free the catch. See Fig 9 .
B2
- Turn mounting and press together control module connector catches.
- Slide the connector from the mounting. See Fig 10 .
B3
TERMINAL REMOVAL
Release the secondary locking with a screwdriver. See Fig 11 .
There are two terminal types:
A. Single locking tab cavity (minitimer terminal)
- minitimer pos. 13, 14, 28, 29, 42, and 43 (see Fig 12 )
B. Double locking tab cavity (microtimer terminal)
-microtimer pos. 1-12, 15-27, and 30-41 (see Fig 12 )
Insert the terminal removal tool into the connector housing cavity from front side. Pull out the terminal from rear side. See Fig 13 and Fig 14 .
B4
TERMINAL REPLACEMENT
Replace terminal using Volvo crimp tool, p/n 999 9323
- Cut off old terminal at end of insulation crimp for minimum wire length loss.
- Remove insulation.
- Position stripped cable in new terminal.
- Hand crimp core wings and insulation wings at the same time using the Volvo crimp tool.
Insert terminal from rear side of connector until it audibly snaps into place (A). See Fig 15 .
Lock the secondary locking (B). See Fig 15 .
B5
Install:
- connector in mounting.
- assemble mounting. See Fig 16 .
- silicon rubber mat on mounting.
Assemble the control module box in accordance with A7-A9.
WARRANTY STATEMENT
Claims may be submitted during the New Car Limited Warranty when a manufacturing defect is present using claim type: 01.
| Operation No. | Labor Description | Time Allowance |
| 37224-3 | Control module box, replace | 0.5 hr. |