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Home >> Volvo >> 2002 >> S60 Base, 2.4 61, Standard >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Climate Units - Removal, Replacement And Installation >> Engine Coolant Heater, Fuel Driven (2001) >> Heat Exchanger, Replacing >> Water Pump Engine Coolant Heater, Replacing >> Adjustment

Water Pump Engine Coolant Heater, Replacing: Adjustment

Extending the wiring for the water pump 

Fig 1: Cutting Off Water Pump Cable Harness Close To Connector
GLL139617Courtesy of VOLVO CARS OF NORTH AMERICA.

Cut off the cable harness for the water pump as close to the connector as possible.

Cut off part of the protective tube so that the 2 cables are exposed.

Strip the ends of the cables enough for the bonded shrink-fit terminals from the kit.

Fig 2: Identifying Taped and Secured Cable Connection
GLL139618Courtesy of VOLVO CARS OF NORTH AMERICA.

Modify the length of the protective tube so that the stripped cable ends are only just protruding.

Thread the thin protective tube onto the cable harness extension.

Use the bonded shrink-fit terminals from the kit. Splice the cable harness extension to the stripped cables.

NOTE: The cable colors must match at each join.

Reinforce the exposed areas. Use insulation tape.

Fig 3: Identifying Protective Tube Threaded Over Joint
GLL139619Courtesy of VOLVO CARS OF NORTH AMERICA.

Thread the thicker protective tube from the kit over the join.

Adjust the length so that it overlaps the thinner protective tubes by approximately 10 mm on each side.

Wind insulation tape around the join.



Extending the wiring for the water pump 

Fig 1: Cutting Off Water Pump Cable Harness Close To Connector
GLL139617Courtesy of VOLVO CARS OF NORTH AMERICA.

Cut off the cable harness for the water pump as close to the connector as possible.

Cut off part of the protective tube so that the 2 cables are exposed.

Strip the ends of the cables enough for the bonded shrink-fit terminals from the kit.

Fig 2: Identifying Taped and Secured Cable Connection
GLL139618Courtesy of VOLVO CARS OF NORTH AMERICA.

Modify the length of the protective tube so that the stripped cable ends are only just protruding.

Thread the thin protective tube onto the cable harness extension.

Use the bonded shrink-fit terminals from the kit. Splice the cable harness extension to the stripped cables.

NOTE: The cable colors must match at each join.

Reinforce the exposed areas. Use insulation tape.

Fig 3: Identifying Protective Tube Threaded Over Joint
GLL139619Courtesy of VOLVO CARS OF NORTH AMERICA.

Thread the thicker protective tube from the kit over the join.

Adjust the length so that it overlaps the thinner protective tubes by approximately 10 mm on each side.

Wind insulation tape around the join.



Extending the wiring for the water pump 

Fig 1: Cutting Off Water Pump Cable Harness Close To Connector
GLL139617Courtesy of VOLVO CARS OF NORTH AMERICA.

Cut off the cable harness for the water pump as close to the connector as possible.

Cut off part of the protective tube so that the 2 cables are exposed.

Strip the ends of the cables enough for the bonded shrink-fit terminals from the kit.

Fig 2: Identifying Taped and Secured Cable Connection
GLL139618Courtesy of VOLVO CARS OF NORTH AMERICA.

Modify the length of the protective tube so that the stripped cable ends are only just protruding.

Thread the thin protective tube onto the cable harness extension.

Use the bonded shrink-fit terminals from the kit. Splice the cable harness extension to the stripped cables.

NOTE: The cable colors must match at each join.

Reinforce the exposed areas. Use insulation tape.

Fig 3: Identifying Protective Tube Threaded Over Joint
GLL139619Courtesy of VOLVO CARS OF NORTH AMERICA.

Thread the thicker protective tube from the kit over the join.

Adjust the length so that it overlaps the thinner protective tubes by approximately 10 mm on each side.

Wind insulation tape around the join.

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