2006 S60 T5 Power loss, stalling, Battery drain, electrical issues CEM Issues [Bad corrosion in 12VDC Bus feed] 9162321 Topic is solved

[Martyd03]

Curious if anyone has some ideas on this.

I had a weird intermittent issue where the acceleration would cut out randomly, then one day it wouldn't start and stay running and would die as soon as I hit the gas. After a few minutes, the car started normally and I drove home with no issues.

Afterwards I parked it for a couple weeks and the battery completely drained. So I charged it up, and I noticed the alarm would randomly sound when parked, and the headlights would randomly turn off and on when it was running.

After I bought an OBD scanner I tried to check what the problem was but now it does nothing, like the battery is still dead, even though it was on a trickle charge the whole time and verified volts with a meter. I tried to jump it and replaced the battery, but nothing happens.

And by dead I mean totally dead with no lights, chimes, dash lights, etc.
Thoughts? CEM possibly?
One thing that worried me was the trunk was cracked open when charging and filled with about 6 inches of water during a bad storm, which surrounded the battery and an electrical component on the passenger side.

[RickHaleParker]

Lift the plastic flap near the fuse box under the hood and check the end of the battery cable.

[Martyd03]

The positive side is still intact, that's where I jump it from.
I'm not sure where the negative connects, but I'm not in a rust prone area either...

[Martyd03]

I'm not sure where the negative connects,

The ground cable (31/53) is on the firewall.

[Martyd03]

The CEM would rather throw some dash lights and messages, have the transmission behave, things like that, not really full engine cut out or battery drain - possible, but I don't remember such evidence from forum talks. But you can always look with a flash light at the CEM from under the dash, look for any traces of water (dried or still leaking). I would rather say as above, that looks like a stupid little wire short somewhere (or ground short). There was just a recent talk about such issue on the forum, just as an exemple viewtopic.php?f=9&t=92688 While there, go ahead and pull the Siren module fuse 38 in the panel near dr door, or if there's none, try to release the connector to the siren (drill a few rivets on the wheel liner, then press the connector tab with a screw driver and pull on it)

[Martyd03]

Thanks guys.
So I went out today and looked for any grounds I could find, but didn't see anything other than a couple of small ones on the fender that I used to verify battery voltage at the post under the hood.
Before tearing into anything else I checked for resistance between the negative terminal and the body, which was .1 ohms, so I think the main ground is good.
I'll pull out the CEM this weekend and inspect it.
Is there some main fuse I should check?
I'll also look for some corroded or loose wires under the car this weekend.

[Martyd03]

OK, so I *think* I found the issue...
Basically there is a box behind the battery with electrical connectors, and it isn't healthy.
Going to replace and see what happens.

[Martyd03]

That would do it. It is fuse box 11E which feeds fuse box 11C, the CEM and the REM.

Fuse box is Volvo part number 9162321.
A new one ~$120.00 + accessories. Self service salvage yard ~15.00 for all.

You don't list where you are in Georgia but, there are at least 10 cars at LQK in Fayetteville, GA that have what you need for less then $20.00 total.



1 Wiring harness, luggage compartment 1.00
2 Main fuse box 1.00 X 9162321
3 Washer 10.00 X 986477
4 Flange lock nut 10.00 X 985865 ; M5
5 Flange lock nut 1.00 X 985866 ; M6
6 Fuel rail 1.00 NS
7 Cap 1.00 X 9162323
8 Fuse 5.00 X

• 40A Fuse 9441937
  50A Fuse 9162326
  60A Fuse 9441938
  70A Fuse 9441939
  80A Fuse 9162327
  100A Fuse 9441940
  125A Fuse 9441941

9 Cable terminal 4.00 X 970793; 2.6-6 mm2
10 Cable terminal 2.00 X 976477; 0-16 mm2
11 Wiring harness 1.00 NS
12 Hexagon nut 1.00 X 987529

[Martyd03]

Welp, that was it!! After some Appalachian engineering, the car's running again.

I'm right outside of Savannah, so I'll hit some part yards this weekend and see what I can scrounge. I might try to get a few, these seem like some handy and simple power distribution boxes.

[Martyd03]

I'm right outside of Savannah,

There are six cars at LKQ Savannah that will have that fuse box.

Look for:
2001 - 2009 S60
1999 - 2006 S80
2001 - 2007 V70
2003 - 2014 XC90