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2007 XC90 Corroded power feed-REPAIRED

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo XC90s. The XC90 proved to be very popular, and very good for Volvo's sales numbers, since its introduction in model year 2003 (North America).
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2007 XC90 Corroded power feed-REPAIRED

Post by precopster » Sun Jun 18, 2017 3:48 pm

A corroded power line resulting in CEM misdiagnosis is what I was dealing with on a diesel 2007 XC90 over the weekend.

You can see in the close-up pic below that high resistance at the point of corrosion resulted in lots of heat and a melted connector.

Symptoms are:

12V available at all fuses however hardly any current for a test lamp (which means high resistance somewhere in the 12V power feed)

No power seat operation (though relays in the seat can be heard clicking)

No driver's door module operation

No passenger door module operation

No climate control fan operation

Pics below of problem:

I repaired it by bypassing the dual connector and splicing in some heavy guage power wire then wrapped with silicone then taped to make a waterproof connection
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IMG_20170616_172721 (Medium).jpg (133.68 KiB) Viewed 293 times
Current cars:2002 XC70, 2006 Ssangyong Rodius (Stavic), 2006 XC90 2.5T, VW Transporter 2.5TDI


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