Reverse Warning System

Reverse warning system












































Reverse warning system

Note! During installation, the underlay must be at a temperature of at least +15°C. A new lining mat is required for cars up to week 13, year 2000. The lining mat must be ordered separately for these cars, P/N 8625515.

- Turn the ignition key to position 0. Remove the key from the switch
- Clean the bumper. Use a mild soap solution.

Note! Wait at least five minutes before disassembling the connectors or removing other electrical equipment




- Remove the rear floor hatch by opening the it and pulling it straight back
- Place the floor hatch to one side
- Turn the knobs on the left and right-hand side of the storage box. Lift out the storage box.




- Remove the two nuts from the front edge of the battery holder. Remove the cover over the battery Then remove the screw from the rear edge. Remove the holder
- Remove the cover
- Disconnect the battery negative lead.




- Remove the folding panels on the left and right-hand sides of the cargo compartment.




- Remove the rear insulation panel from the rear edge of the fuse holder.




- Remove the left side panel by removing the cover and the screw from the front edge
- Pull the top edge of the panel inwards until the clips release
- Fold the panel in. Remove the panel.





Applies only if the car has a lining mat with four perforations:
- Remove the perforated sections (3) from the lining mat.

Applies only if the car has a lining mat with one perforation:
- Remove the lining mat.

Applies to all cars
- Remove the nuts (1) in the rear cross member. This allows the bumper to be removed
- Separate the connector (2) for the aerial.




- Screw out the screw (1) on the left and right hand sides in the rear edge of the wheel arch. Screw the screw almost entirely out
- Press the screw using a screwdriver until the loose end pieces on the inside of the bumper cover are pressed backwards
- Drill out the blind rivet (2) that holds the bumper cover at the lower rear edge of the wheel arch on the right and left-hand sides. Use a 5.5 mm (7/32") diameter drill bit.




- Remove the clips (1) at the bottom of the bumper cover. First press in the centre of the clips until they click
- Pull the bumper backwards slightly. Bend out the sides (2) so that they detach from the mounting (3). Then pull the bumper backwards until it detaches completely
- Place the bumper on a suitable underlay that will not damage the paint.




- Clean the outside of the bumper
- Install the backing paper evenly distributed over the bumper.

Note! The backing paper is used to protect the paint.




- Release the two catches (1) from the upper edge of the bumper on the left and right-hand sides
- Release the fourteen catches (2) from the upper edge of the bumper
- Release the four catches (3) from the centre of the bumper
- Release the five catches (4)
- Remove the foam and the bumper rail from the bumper cover.

Note! Do not remove the aerial from the foam.

- Clean the inside of the bumper.




- Pre drill 3 mm (1/8") diameter holes at the existing marks on the inside of the bumper cover.




- Turn the bumper rail so that the studs point downwards. Place the bumper rail on a suitable underlay
- Remove the foam layer
- Pre drill 3 mm (1/8") diameter holes at the existing marks
- Using the 70 mm (2 3/4") diameter hole saw, drill out the holes through the entire bumper rail
- When the hole saw reaches the bottom, turn the bumper rail. Drill from the other side.

Note! Use a long central drill bit with the hole saw.




- Install the foam and the bumper rail in the bumper cover
- Drill through the bumper cover and the foam. Use a 3 mm (1/8") diameter drill bit in the four pre-drilled holes. This is to make a mark so that the holes for the sensor and holder can be drilled in the foam
- Remove the bumper rail and foam from the bumper cover.




- Drill through the four pre drilled holes in the foam. Use the 70 mm (2 3/4") diameter hole saw.




- Drill out the bumper cover. Use a 9 mm (23/64") diameter drill bit
- Open the holes in the bumper casing. Use a 31 mm (1 7/32") diameter hole cutter (P/N 9814069).




- Wash away any dirt and stones from the bumper cover by the holes. Use a mild soap solution
- Clean around the drilled holes. Use cleaner H (P/N 1161436-9), or a wet cloth. Allow to dry
- Apply primer (P/N 8637076) around the holes. Allow to dry.




- Clean the mating surface on the holders for the sensors. Use cleaner H (P/N 1161436-9), or a wet cloth. Allow to dry
- Apply primer (P/N 8637076) on the cleaned surfaces of the holder. Allow to dry.




- Remove the yellow protective film from one side of the tape
- Place the tape on the sensor holder
- Carry out the previous procedure on the remaining three holders.




- Remove the protective film from the orange pieces of tape on the holders
- Install the holders for the sensors. The narrow side must be pointing upward. Install horizontally in line with the bumper casing, as illustrated.

Note! Ensure the tape is correctly positioned; the tape adheres immediately. The function may be impaired if the sensors are not positioned correctly.




- Place the foam in the bumper cover
- Connect one of the sensors to one of the cable harness connectors
- Push one of the sensors with the connector down towards one of the sensor holders. Mark out how much more foam needs to be cut out so that the sensor and connector fit into the sensor holder
- Repeat this procedure for all sensors. Cut out where necessary
- Use a 29 mm (1 1/8") diameter hole saw to cut the three holes, counting from the left. Cut out the right hand hole using a utility knife or similar.




- Cut out the recesses in the foam for the sensor wiring as illustrated
- Cut out the recess (1) so that the main cable harness going into the car can be inserted.




- Clean the inside of the bumper where the cable harness will be secured. Use primer (P/N 8637076)
- Reinstall the foam in the bumper cover.




- Connect the cable harness connectors to the sensors.

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

- Install the sensors in the holders
- Secure the cable harness using butyl tape.




- Secure the sensor wiring in the cut outs in the foam using pieces of butyl tape (1) as illustrated. Then route the cable harness (2) up into the hole in the bumper rail.




- Install the bumper rail. Check that the outer sensors and connectors do not catch components on the reverse of the bumper rail
- Cut out where necessary. The illustration displays where cutting might be necessary
- Lift out the bumper rail. Cut out using a utility knife.




- Reinstall the bumper railing in the bumper cover
- Pull up the cable harness (1) from the hole (2) for the sensor in the bumper rail
- Press the bumper rail into place in the bumper cover, ensure that all catches engage
- Secure the cable harness in the bumper rail using pieces of butyl tape (3).




- Cut off the rubber bushing on the cable harness
- Lift the bumper into position
- Route the cable harness for the sensors through the existing hole in the rear cross member. Continue to the right in the gap in the rear cross member. Continue out through the hole for the left mounting for the bumper behind the battery
- Remove the left screw (1) in the tailgate sill trim panel
- Pull the panel upwards until it clicks. Then insert the cable harness in the gap between the left floor support and the sill on the tailgate.

Note! Ensure that the cable is not trapped.

- Press the sill trim panel back into place. Tighten using the screw.




Note! Ensure that the loose mountings (A) for the sides of the bumper are in position on the right and left sides.

Reinstall the bumper. Locate the ends of the bumper (1) in the rails (2). Push in
- Reinstall and tighten the nuts. Tighten to 18 Nm (13 lbf. ft.).

Applies only if the car has a lining mat with four perforations. See point 7





Install the rubber tabs (from the kit) over the four installed nuts as follows:
- Align the rubber tabs (1, 4) edge to edge with the lining mat. If necessary, cut away the area (1) around the nut so that the nut is accessible
- Press the rubber tab (2) together slightly to align in the cut out
- Align the rubber tab (3) so that the lower edge is positioned edge to edge with the lining mat. Cut off the section protruding over the lining mat. (Do not cut off an excessive amount)
- Make a cut (using a knife) in one rubber tab (4). This is so that the cable harness for the sensor can be inserted.

Applies only if the car has a lining mat with one perforation. See point 7:
- Install a new lining mat.

Applies to all cars:
- Reinstall the aerial connector.

- Tighten the bumper cover using the screws at the rear of the wheel arch on the right and left-hand sides
- Secure the bumper cover using blind rivets at the lower rear edge of the wheel arch on the left and right-hand sides
- Reinstall the four clips on the underside of the bumper in the centre.

Note! Do not remove the backing from the bumper yet. The backing will be needed later when painting the sensors and sensor holders.




- Mark the surfaces for the location of the Velcro strips on the control module. Also mark the front edge of the air vent in the rear left wheel arch
- Install the Velcro strips
- Connect the wiring from the sensors and the two-pin cable (from the kit) to the control module
- Install the control module.




- Set the buzzer to the loudest volume. Turn the outer section in relation to the inner section until the existing marks are opposite each other
- Lock in position using a piece of tape. Take the buzzer (1) and the clip (2) and secure them at the edge on top of the inside of the panel. See the illustration
- Connect the two-pin cable (3) from the control module to the cable for the buzzer
- Secure the cable around the insulation panel. Use pieces of butyl tape (4), as illustrated
- TEXT.




- Remove the lower six-pin grey connector in the left tail lamp. Push in the catches on the lower edge. Pull the connector out.





Open the catches on the connector:
- Press down the catches. Pull the orange tab out as far as it will go
- Carefully pry apart the connector so that the remaining lock lug on the orange catch is released
- Remove the orange lock.




- Remove the wiring from the connector. Insert a pointed object in the space under the relevant cable terminal. Press together the sprung catch. At the same time, pull the cable out
- Remove the black (SB) cable from terminal 6
- Cut off the cable terminal. Twin the cable terminal with the black (SB) cable which goes to the control module
- Install a new cable terminal, (P/N 9168510). Connect the new cable terminal to terminal 6 in the connector
- Remove the blue (BL) cable from terminal 4
- Cut off the cable terminal
- Take the switch from the kit. Twin one of the cables with the blue (BL) cable
- Install a new cable terminal (P/N 9168510). Connect the new cable terminal to terminal 4 in the connector
- Reinstall the orange catch on the connector. Press the catch into place
- Install a cable connector (1) between the red (R) cable from the switch and the red (R) cable from the control module. Connect these together
- Reinstall the connector in the tail lamp.




- Position the switch on the air vent as illustrated. Repeat in the same way as for the installation of the control module
- Clamp the wiring. Use tie straps from the kit
- Clean the visible surfaces on the sensor holders and sensors. Use a wet cloth. Allow to dry
- Apply a thin layer of primer (P/N 8637076) over the sensors and the sensor holders. Allow to dry for at least 10 minutes.
- Spray the sensor holders and the sensors. Use the same colour code as the car. Use Volvo recommended paint. Only paint the parts that will be visible after installation.

Note! Apply a maximum of two layers of paint. Too many layers of paint may have a negative impact on the function of the sensors. However, the sensors must be painted for optimal functionality.

- Remove the backing from the bumper when the paint has dried.

- Connect the battery negative terminal
- Reinstall the battery cover and holder
- Reinstall the left side panel. Ensure that the cable for the buzzer is not trapped
- Reinstall the rear small insulation panel
- Reinstall the folding panels
- Reinstall the storage box
- Reinstall the rear floor hatch
- Check the function of the reverse warning system.