CUO on wiring harness (connector of unknown origin)
 

Hi everyone,

I was troubleshooting another problem on my car (dead horn) and
began tracing the wiring harness in the engine compartment when I
found this large connector just hanging loose in front of the battery
tray. I can't see anything that it could connect to and I can't find
it listed in the wiring diagrams that I have. Anyone know what this
is for?
My car is a 96 850 n.a. and this connector is really large and has
2 mounting ears that have screw holes for mounting it to something.

John

RE: CUO on wiring harness (connector of unknown origin)
 

John that sound very much like the headlight wiring connector? Do you have working headlights??

RE: CUO on wiring harness (connector of unknown origin)
 

Maybe it is the Headlight wiper motor plug.

RE: CUO on wiring harness (connector of unknown origin)
 

No wiper motor plug is 2 pin no flange and is small. He is def. describing the headlight plug

RE: CUO on wiring harness (connector of unknown origin)
 

Hi John,

I hope you're well.

It seems that a lot of people have been finding "empty" connectors lately, I wonder if it was a conspiracy by Volvo:(?

Anyway, if the connector does not go to the headlight/wiper sections, you could perhaps search around the "relay bay" at the top of the radiator? There are quite a few relays & electrical components installed, but if you have not noticed any problem, it was probably meant for an option like, well, an emergency ejection seat[8D]?

BTW, I have agreed to be a Moderator. I hope to make the forum better, friendlier and benefit those who are having trouble with their Volvos but cannot afford all the repairs. And I also want it to be sarcasm/offensive attitude-free environment.

Anyway, good day to you and see you around.


JPN

RE: CUO on wiring harness (connector of unknown origin)
 

Hi everyone,

Thanks for the quick replies. I should have given more information
but I thought someone might recognize this connector right away.

This is a gigantic rectangular connector with about 27 locations
available for pins. It has pins installed in about 14 locations and
a huge bundle of wires going into it. It comes off the harness
where the harness goes between the bottom of the radiator
and the headlight on the driver's side. This large connector is
just hanging loose to the right front of the battery tray. It looks
like it would go to some sort of control module or connect
2 wiring harnesses together.
Everything on the car works fine except the headlight wipers,
cruise control, ABS(bad module?) and horn. I've driven the car
for 6 months with no problems or codes.
Someone did repairs on the left front of the car and replaced
the headlight with a single bulb unit and the parking light is taller
than normal, it fills the entire opening from top to bottom. They
also cut 2 bundles of wires (black, green,blue, and black,green,
white). These wires are just hanging out of the harness, and I
can't identify them either.
Could the front harness have been swapped with one from
another year (or volvo model)?
LOL.... maybe this car WAS equipped with a new ejection seat
safety feature.

Kanji, congratulations on your promotion to moderator. I know
you will add to the quality of this forum as you have always done.
You, tech, and the members make this a very enjoyable and relaxed
forum, unlike many others on the internet.

Thanks and best regards, John

RE: CUO on wiring harness (connector of unknown origin)
 

Hi John,

Thanks, but it is also a member like you, who makes this forum a sarcasm-free environment. I've been seeing many members here who are conscientious and are willing to help others. That's probably the top reason why I don't bother any other forum.

As to the connector, I think whoever had done the head light repair might have done something they shouldn't have. I'll check the electrical diagram to see if I can come up with something, but please allow me a bit of time, as working in Japan is super-ultra stressful and I'm about to collapse[X(].

Thanks again,


Kanji/JPN

RE: CUO on wiring harness (connector of unknown origin)
 

If all else fails maybe one day we can meet up and I can scope out what it is for.

RE: CUO on wiring harness (connector of unknown origin)
 

Kanji, I agree the members and moderators on this forum are
mature, intelligent, and professional. I'm sorry to hear about your
work situation there. I hope things go better for you and you are
able to relax and get some rest soon.

Tech, yes that would be great, your advice would be a great help.
Maybe sometime when you have a few minutes and it is convenient
for you.


Thanks and best regards, John

RE: CUO on wiring harness (connector of unknown origin)
 

John, can you post a picture of the connector?

RE: CUO on wiring harness (connector of unknown origin)
 

Hi axelm,

How have you been? Unfortunately I don't have a camera
or a diagram with a drawing of the connector.

Thanks, John

RE: CUO on wiring harness (connector of unknown origin)
 

John,

Follow the connector back along the wiring. I will bet $$ that they spliced in a connector for the single headlight and left the old connector for the double unit there. The ONLY connector that is like you describe in that area of the car is the headlight connector.

RE: CUO on wiring harness (connector of unknown origin)
 

Hi 1996850turbo,

Thanks for your help. The ironic thing is that the headlight wiring
is one of the only things I can positively identify. When the last
owner put in the wrong headlight, they cut off the original headlight
connector and replaced it with one that fit the replacement light.
They just twisted the wires together and used electrical tape.
When I put in the correct light I crimped on some "slip-on" terminals
to plug onto the light.

The unknown connector is very large. It is sorta rectangular with
14 pins and unpopulated positions for about 13 more and a large
bundle of wires going into it. From where the bundle breaks out of
the harness to the connector is roughly 18-24 inches so it looks
like it should connect to something near the headlight, the battery
tray, or maybe near the bottom or side of the radiator.

Best regards, John

RE: CUO on wiring harness (connector of unknown origin)
 

BEEP! BEEEEP!
Woohoo! My horn works...finally after 8 months....I have
to go celebrate...I'm excited! Maybe the following scenario:

Mr H: Isn't that our weird neighbor, the one that is always
working on his car?
Mrs. H: Yeah the one from a couple streets over with the Volvo.
Mr H: Why does he keep driving round and round the block
blowing his horn? There's something written on the windows
of his car.
Mrs H: Oh I think he must have just gotten married and he wants
everyone to know. That's so sweet!
Mr H: But he's the only one in the car and I think he's already
married.
Mrs H: Well here he comes again, see what it says.
Mr H: It says...." I just fixed my horn...an I'm gonna use it...
an if you don't like it..you can %#@*."
Mrs H: EEEEK! That's not sweet at all. I'm calling the police!

Well maybe I wouldn't go that far! Explanation will follow.
First I have to figure out the default font size on this thing
again LOL.

John

RE: CUO on wiring harness (connector of unknown origin)
 

John,

I'm so glad, so glad that you are joining my "Suggested Scenario Club". Tech will be in tears fordivine joythat there is another member who can contribute to the heart-warming, make-your-day-guaranteed scenario:).

BTW, is the connector still hanging around?

Well done for the horns. Be sure to park right in front of the neighbor and share the joy of rejuvenated device:).


JPN

RE: CUO on wiring harness (connector of unknown origin)
 

LOL that's awesome.

That must be how my neighbors look at me when I'm working on my car. I also learned that technically I'm not allowed to work on my car at my apartment complex, oh well. Until someone yells at me I'm not stopping.
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RE: CUO on wiring harness (connector of unknown origin)
 

Ok, in case someone else runs into this mystery connector and wires
here is what I've found.
On early 850's the bottom of the header panel had a harness that
went across it and connected to the headlights, headlight wipers,
corner lights, and horn. This "header harness" connected to the
main harness on the left side of the engine compartment near the
battery via the large connector that I found.
On newer 850's there is no "header harness". The wires for the
headlights,headlight wipers, and corner lights run directly down the
left and right sides of the engine compartment to their respective
lights and there is no need for the "header harness" or the large
connector. The horn wires run across the header panel from the
left side harness.
On my car (a 96) someone had replaced the header panel with
a panel from an early 850, but they did not remove the "header
harness". There was no connector to plug the "header harness"
into and instead of connecting the horn wires across from the
left side harness, they just cut the wires off. They also cut off
the left side headlight and corner light wires from the "header
harness". Hence no horn, a bunch of unidentifed wires that had
been cut, and a huge unidentified connector.
This was an example of shoddy repair work at it's finest. It
would have taken 5 minutes max to remove the "header harness"
and connect the horn wires from the left side harness. The worst
part is that this was done by my bosses friend (a dealer) whom
he paid for the work.
Just for information the large connector for the early 850
"header harness" is listed as part 24/16 on page 12-24 of the
Haynes manual. It is not shown on the wiring diagrams that I
downloaded from the internet.

Kanji, your "suggested scenarios" always make me laugh. They
are my inspiration. My nearby neighbors are all very nice and I
think they have had a more than ample share of joy during the
testing of my rejuvinated(horn) device. LOL

Info2x if you jerk your head erratically from time to time, mumble
incoherent phrases when others are near and glare at people as
they walk by maybe no one will bother you while you work on
your car. If that doesn't work go to the nearest Wal Mart parking
lot. No one will question you working on your car there and people
will probably offer to help you. If you don't have a Wal Mart then
go to the parking lot of your nearest auto parts chain. Almost as
good as Wal Mart :-)

Best regards, John

RE: CUO on wiring harness (connector of unknown origin)
 

haha! Well I'm moving out of this place on wednesday going back to school for another semester or two, depends on if I feel like graduating.

It is illegal here in MI to work on a car in an auto store lot. They all have signs to that effect as well.
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RE: CUO on wiring harness (connector of unknown origin)
 

Glad you got it figured out!!!!

P.S. I was rolling on the floor

RE: CUO on wiring harness (connector of unknown origin)
 

Thanks tech. I'm sure the neighbors thought I had really lost it when
I started "repairing" my car by pulling large handfulls of wires out
of the front and throwing them away. LOL
Your new 850 is looking good, the donor didn't look bad either.
Are you going to get it running?

info2x good luck on your classes and graduation, I'm sure you'll
do very well. And don't forget, with some old clothes and a
couple of 2x4's sticking out of the trunk there's always the
Home Depot lot....

Best wishes to everyone, John