2.1 Pin/Pin sockets and 3.5 Pin/Pin sockets

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2006 Volvo S80, 2005 Volvo S80, 2004 Volvo S80, 2003 Volvo S80, and 2002 Volvo S80. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: 2.1 Pin/Pin Sockets And 3.5 Pin/Pin Sockets

GLL101272

Courtesy of VOLVO CARS OF NORTH AMERICA.

Terminal removal tool, p/n 981 4230

For round cavity openings a terminal removal tool with a hollow end is used.

The terminal removal tool is used for the following cable terminals:

Fig 2: 2.1 Pin/Pin Sockets (1 Of 2)

GLL101301

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 3: 2.1 Pin/Pin Sockets (2 Of 2)

GLL101302

Courtesy of VOLVO CARS OF NORTH AMERICA.

A 2.1 Pin/Pin sockets

Fig 4: 3.5 Pin/Pin sockets (1 Of 2)

GLL101303

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 5: 3.5 Pin/Pin sockets (2 Of 2)

GLL101304

Courtesy of VOLVO CARS OF NORTH AMERICA.

B 3.5 Pin/Pin sockets

Fig 6: Identifying Two Cavity Opening Sizes

GLL101249

Courtesy of VOLVO CARS OF NORTH AMERICA.

Choose a terminal removal tool with the correct diameter

There are two cavity opening sizes.

See illustration.

Choose a terminal removal tool which matches the cavity opening.

The smaller end is for diameter 2.1
The larger end is for diameter 3.5

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 Using terminal removal tools which give the correct working procedure.

Proceed to chapter New cable terminal Seal SWS and plug . Replacing a cable terminal in order to crimp a new cable terminal.