Installation instructions, accessories - Front …ftp.clubvolvo.ru/CARS DOCS AND SOFT/Installation...5 R8601457 Detach the front bumper Detach the connectors for the fog lamps (4)

XC90Section Group Weight(Kg/Pounds) Year Month

3 36 0.53/1.17 2005 02

Replaces issue: 2004 09

XC90Section Group Weight(Kg/Pounds) Year Month

3 36 0.53/1.17 2005 02

Replaces issue: 2004 09

Installation instructions, accessories - Front parking assistance Volvo Car Corporation Göteborg, Sweden


© VolvoCar Corporation, 2005 Printed in Sweden 30660434© VolvoCar Corporation, 2005 Printed in Sweden 30660434

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Required tools

A0000162 A0000163 A0000161 A0000180 A0801178 A0000172 A0000192 M0000232 A0000214 A0000177

R3603731

IMG-213320




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Page 3 of 19

INTRODUCTION

● NOTE! Read through the entire text before carrying out any work.

● The front page gives the date of this edition and the edition it replaces

● The second page shows the tools needed for the installation and the contents of the installation kit

● The illustrations display the procedure in order of operation. The order of operation is repeated in the text section

● Cut out the text page in order to follow the illustrations and text at the same time.

Front parking assistance

Note!

During installation the underlying surface must maintain a temperature of at least +15° C (60° F).

Note!

This accessory is connected to the car's electrical system. It requires software unique to the car.




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1

A3000265

● Turn the ignition key to position 0. Remove the ignition key from the ignition switch.

Note!

Wait at least one minute before unplugging the connectors or removing other electrical equipment.

2

R8601454

Detach the front bumper

● Open and raise the bonnet

Remove:● the clips underneath the bumper, x 2 (1 on each side)

● Detach the sides of the bumper by pulling them diagonally up and outwards.

3

R8601455


Remove:● The covers for the high-pressure headlamp washing (1)

● The covers for the screw mounting

● Screws (2) x 2

4

R8601456


● Pull the bumper straight out/forwards.

● Detach the snap-on coupling (3) for the washer hose.




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5

R8601457


● Detach the connectors for the fog lamps (4).

● Remove the bumper.

6

R8601458


● Detach the two clips holding the rear section in the bumper by pressing the clips in the centre and then pulling them out.

● Detach the rear section from the bumper by pulling apart all plastic catches.

● Detach the bumper foam.

Note!

The plastic catches are fitted securely. Detaching the catches requires considerable force so be careful with the bumper. Pull and coax from different angles until all catches have released.

7

R8601459


● Apply the protective backing paper to the bumper.

● Take the bumper bar from the kit.

● Separate the protective backing paper and affix on the bumper bar.

8

R8505177

Preparations in the passenger compartment

● Detach the sill (1) and the right-hand panel (2) of the centre console.




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9

R8504294


● Detach the floor carpet at the front passenger seat and fold it aside so that the hole to the engine compartment is visible.

10

R8504171


● Remove the panel in the front right-hand seat mounting by pushing up the catch (1) on the top and pulling the panel forwards.

11

R8504172


● Fold the backrest forward and push the seat as far forward as possible. (On cars with two rows of seats the second row is fixed.)

● Remove the cover (1) to the rear right-hand seat mounting by prizing it away at the rear edge.

12A

R8504173


Illustration A

● Detach the right-hand rear door's sill trim panel by pulling it away at the rear edge so that the clips release. Continue forward until the remaining clips have released.

Applies to cars with two rows of seats● On cars with two rows of seats the seat cannot be pushed forward. To remove

the sill trim panel, start by folding the backrest forward as the sill trim panel is pulled away at the rear edge. Following which, move the backrest back so that the seat cushion can be raised, and in this way increase the space for removing




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12B

R8504174

the sill trim panel. It is fixed securely, so make sure that there is no damage to it or to adjoining components during removal.

Illustration B

● Unhook the sill trim panel from the B-pillar panel and place it in the second/third row of seats.

13

R8503999

Preparations in the cargo compartment

Applies to cars with three rows of seats and integrated carrier bag holder on the underside of the centre floor hatch

● Fold up the centre floor hatch.

● Detach the two belts on the panel under the floor hatch and lift up the panel at the rear edge.

● Fold the floor hatch back and lift out the floor hatch with panel.

Applies to cars with three rows of seats without an integrated carrier bag holder

● Lift up the centre rear floor hatch at the rear edge and lift it out.

Applies to cars with three rows of seats● Remove the two centre floor hatches by first lifting them up slightly at the rear

edge and then pulling them away from their mountings at the front edge.

● If the centre rear floor hatch is equipped with a carrier bag holder on the underside then the floor hatch is secured with a belt on each short side of the storage box. Detach these belts.

● Remove the two storage boxes under the floor hatch.

14

R8504158


● Remove the right-hand side floor hatch (1).




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15

R8504159


● Remove the folding side panel from the right-hand side of the cargo compartment.

16

R3703756

Installing the cable harness from the bumper

● Take the short cable harness from the kit.

● Detach the smaller connector from the cable.

● Install the waterproof connector (1) with tie strap/metal clip from the kit.

● Secure the tie strap around the connector and install the metal clip around the panel edge on the right-hand side of the car.

17

D2102942

Installing the cable harness from the bumper

● Pull the end of the cable with the loose pins into the engine compartment.

● Route the cable (1) as illustrated. Place it under the cable duct and expansion tank so that it is concealed.

● Clamp it in with tie straps from the kit.

Note!

Make sure that the cable is positioned so that it is not damaged by heat or wear.

18A

D8200205

Cable routing to the passenger compartment

Illustration 18A shows the version in a left-hand drive car.

Applies to left-hand drive cars. ● Raise the car.

● Remove the plug from the hole into the passenger compartment.

If the car has a rubber grommet without any space for more cables: ● Remove the existing rubber grommet and replace it with the rubber grommet from

the kit. Cut off the tip of one of the rubber teats.




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18B

IMG-217620

If the car has a rubber grommet with space for more cables: ● Cut off the tip of the unused rubber teat.

Applies to all models● Lubricate the cable with normal soap so that the cable slides easily in the rubber

grommet.

● Thread the rubber grommet on the cable.

● Route the cable in through the hole and press in the rubber grommet so that it seals properly.

● Pull the cable again so that the correct length remains outside the passenger compartment.

● Make sure that the cable's heating hose is in contact against the rubber grommet and secure it with a tie strap.

Illustration 18B shows the version in a right-hand drive car.

Applies to right-hand drive cars. ● Locate the rubber grommet for the bonnet catch cable.

● Cut off the tip of an unused rubber teat.

● Thread welding wire for example through the rubber grommet and tape the cable onto the welding wire.

● Lubricate the cable with normal soap so that the cable slides easily in the rubber grommet.

● Route the welding wire and cable in, and through the rubber grommet.

● Adjust it so that the correct length remains outside the passenger compartment.

● Seal between the rubber grommet and cabling by fitting a tie strap around the rubber teat.

● Make sure that the cable's heating hose is in contact against the rubber grommet and secure it with a tie strap.

19

J3703487

Cable routing in the passenger compartment

● Take the connector from the kit.

● Undo the catch

● Install the cable end pins in the connector.

1. Blue (BL)

2. Green (GN)

3. Violet (VO)




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4. Yellow (Y)

5. White (W)

6. Black (SB)

● Press back the connector's catch.

20

R8505178


Cable routing to the ECU control module● Take the long cable from the kit and connect it to the connector which has just

been prepared.

21

R3702904


● Guide the cable down between the carpet and the door sill as far as possible to the floor and route it along the right-hand side of the car on to the rear edge of the right-hand rear door's opening.

● Route the cable by the front right-hand seat mounting on the right-hand seat in the second row of seats.

● Pull away the mat from the front edge of the right-hand side panel in the cargo compartment.

● Route the cable harness along the right-hand side of the right-hand seat in the second row of seats, towards the front edge of the rear wheel housing.

● Route it further on the left-hand side of the seat belt's lower mounting, between the support bracket for the right-hand seat and wheel housing, and out at the left-hand side of the wheel housing.

● Clamp the cable harness into the hole in the seat mounting front member, and in the rear hole in the horizontal panel at the right-hand side of the seat. Use tie straps (1) from the kit.




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22A

R3702907

22B

R3703023

Cable routing in the cargo compartment

Illustration A

Applies to cars with three rows of seats● Guide in a wire or cable (1) at the rear edge of the right-hand side panel and

along its inside, above the load securing eyelet brackets.

● Route the wire/cable to the front edge of the side panel.

Illustration B

● Tape the cable (2) to the wire and route it on at the rear edge of the side panel.

23

R3702935


Applies to cars with two rows of seats● Route the cable on the left-hand side of the seat belt's mounting at the front edge

of the wheel housing, inside the carpet at the front edge of the side panel, between the side panel and the rear cargo floor support, to the tailgate.

24A

R8505188


Illustration A

● Continue to route the cable along the existing cable harness below the tailgate.

● Secure the cable with tie straps from the kit.

● Remove the left-hand floor hatch (1).

Illustration B




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24B

R8504080

● Remove the folding side panel from the left-hand side in the cargo compartment.

25

R3905354


● Connect the cable in an unused port in the control module which is secured with Velcro on the left-hand side in the cargo compartment behind the wheel housing.

Note!

Make sure that the connector clicks into place and is properly secured.

26

R8505187


Applies when the rear side panel must be removed to facilitate cable routing. Remove:

● the hatch in the rear edge of the side panel.

● four covers.

● four screws.

● one clip.

● any A/C controls.

● Detach the C and D panels at the lower edge.

● Pull the side panel away and lift it off.




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27

R8601450

Making the holes for the sensors.

● Measure out and mark up for the holes for the outer sensors. Measure 176 mm (6 7/8") from the line marked Y600. Mark up 5 mm (13/64") below the line marked Z1200 as illustrated

28

R8601451


● Pre-drill the holes in the markings on both sides with a 3 mm (1/8") diameter drill bit. Following which, drill out the holes to 8.5 mm (21/64").

29

R8601444


● Take the bumper bar which had the protective tape affixed.

● Pre-drill the holes in the markings (1) on both sides with a 3 mm (1/8") diameter drill bit. Following which, drill out the holes to 8.5 mm (21/64").

30

R8601474


● Reinstall the foam and rear section loosely in the bumper but without securing it to all of the catches.

● Make sure that the rear section is in the correct position by engaging a few of the catches.

● Drill through the outer 8.5 mm (21/64") holes in the side panels of the bumper and straight through the rear section.




Page 14 of 19

31

R8601445


● When installing the bumper bar, follow the enclosed separate installation instructions.

●

Drill straight through the bumper bar's holes and through the bumper behind them.

● Remove the bumper bar again.

Note!

If the car already has a bumper bar then this must be removed and replaced with the bumper bar from the kit.

Note!

Install the bumper bar temporarily in the correct position without securing it with tape.

32

R8601443


● Open the holes in the bumper bar using a 31 mm (1 /32") hole punching tool part no. 9814069.

● Open the outer drilled holes in the bumper using a 31 mm (1 /32") hole punching tool part no. 9814069 .

● The illustration shows the hole positions in the bumper bar.

33

R8601441


● Make extra recesses to the right of the 8.5 mm (21/64") holes in the bumper. See Illustration A

● Drill straight through the bumper, foam and rear section in one action.

Note!

Applies only to the two inner holes in the bumper.




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34

R8601440


● Detach the rear section, foam and bumper bar from the bumper and blow away all filings.

● Make recesses in the rear section for the sensors' connectors at the outer holes as illustrated. Use the 8.5 mm (21/64") holes as guides for the hole saw. A lathe hole saw can be used to make a single large hole. Also, cut out a little extra to the right with a jig saw or similar.

If the recess is too small then the assembly of the bumper with all components will be troublesome and the sensor cables can then become damaged.

● Do this on both sides of the bumper.

35

R8601460

Installing the sensor holders

● Clean out the dirt out from the inside of the bumper cover using a mild soap solution.

● Clean around holes and their inner edges using a cleaning cloth, part no. 9192678, and allow to dry.

● Apply a thin layer of activator, part no. 8637076, on the cleaned surfaces around the inside of the holes and allow to dry.

36

IMG-214381


● Clean the sensor surface (1) on the sensors using a cleaning cloth.

● Clean surfaces 2 and 3 on the sensor holders using a cleaning cloth.

● Allow to dry.

● Apply a thin layer of activator on the cleaned surfaces and allow to dry.

37

D3603622


● Remove the protective backing tape from one side of the tape. Apply the tape on the front side of the sensor holder.

● Carry out the procedure above for the three other sensor holders.

● Remove the protective film from the affixed pieces of tape on the sensor holders.

● Install the sensor holders with the narrow edge up. The top edge of the sensor holder must be horizontal with the bumper.

Note!




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The tape adheres immediately. Incorrect positioning of the sensor holders can result in the function being out of order completely or temporarily.

38 Installing the sensor holders

● Install the bumper bar, in accordance with the enclosed separate installation instructions.

39

R8601448

Installing the sensors and cable harness

● Take the sensors and their cable harness from the kit.

● Fit the all of the sensors in the sensor holders so that they fasten securely.

● Connect the cable harness connectors to the sensors.

● The cable harness must by secured up above the foam, along the edge inside the bumper cover. Secure the cable with butyl tape. Use activator (part no. 8637076) as a basis in order to increase adhesion.

Note!

A click should be heard when connecting. The noise confirms that the catch has locked.

40

R8601461


● Reinstall the foam and the plastic in the bumper cover.

● Check that the sensor cable is not routed between the bumper and the foam as it would then be awkward to assemble the components.

Note!

Make sure that all catches fully engage.

41A

R8601449


Illustration A

● Spray the inner sensors and the visible sections of their holders with Silverstone paint (part no. 9437338)

Note!

Take care that the activator, and any previous layers of paint, has dried for at least ten minutes before the paint is sprayed on.




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41B

R8601447

● Apply a maximum of two layers of paint.

Caution!

Too many layers of paint may result in partial or complete malfunction.

Illustration B

● Take the clear coat included with the Silverstone paint. Spray the two outer sensors and the visible sections of their holders with clear coat.

● Apply a maximum of two layers of clear coat.

Caution!

Too many layers of clear coat may result in partial or complete malfunction.

Note!

Only the inner sensors and their holders shall be painted with Silverstone.

Note!

Clear coat must be applied to the sensors in order to obtain the correct function and protection against discoloration.

42

R8601452


● Hold the bumper up against the car and connect the connector for the sensors to the connector clamped to the car.

● Reinstall the bumpers by repeating the instructions in steps 2-5 in reverse order.

43 Installing the sensors and cable harness

● Clamp the sensor cable so that it is not chafed or causes noise.


Reinstall:● the sills, front and rear.

● the side panels in the cargo compartment.

● the floor carpet.




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● Programme the software in accordance with the service information in VIDA.




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Documents

Installation instructions, accessories - Front …ftp.clubvolvo.ru/CARS DOCS AND SOFT/Installation...5 R8601457 Detach the front bumper Detach the connectors for the fog lamps (4)