Reverse Warning System

Reverse warning system












































Reverse warning system

Note! During installation the underlay must be kept at a temperature of at least +15°C (60°F).

- Turn the ignition key to position 0
- Remove the ignition key from the ignition lock.

Note! Wait at least one minute before disassembling the connectors or removing other electrical equipment.

- Clean the bumper. Use a mild soap solution.




- Fold the cargo compartment carpet (1) to one side
- Turn the clips (2) for the left and right side panels. Remove the clips and the plastic nut. Remove the panels
- Remove the two covers (3). Slacken off the two screws (4) from under the cover. Grip the outer edges of the panel (5). Pull the panel inwards towards the centre so that the clips release at the sides. Disconnect the connectors (6) for the cargo compartment lamps
- Remove the panel by pulling it straight upwards so that the clips release from the rear cross member.




- Remove the rubber seals on the nuts (1)
- Remove the nuts (1) for the rear bumper
- Separate the connector (2) for the aerial.




- Raise the car
- Remove the rear wheels
- Carefully drill out the rivets holding the bumper cover on both sides. Use a 6 mm (1/4") diameter drill bit. Do not damage the plastic components.




- Remove the bumper by pulling it straight backwards
- Place the bumper on an underlay that will not damage the paint.

Preparing the bumper




- Clean the inside of the bumper
- Install the backing paper. Evenly distribute the backing over the bumper.

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

Disassembling the bumper




- Remove the four clips (1) on the inside of the top edge of the bumper
- Remove the ten outer and four inner lock facings (2) at the upper edge
- Remove the lower lock facings (3)
- Remove the foam from the bumper casing.

Note! Do not remove the aerial from the foam.

- Clean the inside of the bumper.




- Find the centre of the bumper. The centre is marked with two crosses on the inside of the bumper cover
- Draw a guide line between both crosses. Use this guide line as a starting point when measuring the horizontal measurements. For the vertical measurements; start from the underside of the reinforcement (1). Mark out 22 mm (7/8") downwards
- Mark the position of the sensor holders, as illustrated.




- Pre-drill 3 mm (1/8") diameter holes at the markings. Drill from the inside of the bumper
- Drill out the pre-drilled holes using an 8.5 mm (21/64") diameter drill bit.




- Open the holes in the bumper casing. Use a 31 mm (17/32") diameter hole cutter, (P/N: 9814069).

Cleaning and taping the mating surfaces on the inside of the bumper




- Wash any dirt and stones off the bumper casing. Use a mild soap solution
- Clean around the drilled holes using cleaner H, P/N 1161436-9 or a wet cloth. Allow to dry
- Apply primer (P/N 9192679) 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 the primer (P/N 9192679) to the cleaned surfaces of the holders. Allow to dry.




- Remove the yellow protective film from one side of the tape
- Place the tape on the sensor holder
- Carry out the above procedure on the remaining 3 holders.

Installing the 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.

Installing the sensors




- 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.

Assembling the bumper




- Clean the inside of the bumper where the cable harness will be secured. Use primer (P/N 9192679)
- Secure the cable harness using butyl tape
- Assemble the components for the bumper.

Drilling the body




- Mark a hole for a lead-in for the cable harness as illustrated
- Drill an 8.5 mm (21/64") diameter hole at the marking
- Open the hole in the bodywork. Use a 31 mm (1 7/32") diameter hole cutter, (P/N: 9814069).

Note! Rust-proof the edges of the hole.

- Clean the sensor holder using a wet cloth. Allow to dry
- Apply a thin layer of primer 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.

Routing wiring




- Lift the bumper into position
- Route the cable harness for the sensors through the hole on the side. Install the rubber grommet
- Reconnect the aerial connector.




- Reinstall the bumper. Locate the ends of the bumper (1) in the rails (2). Push the bumper in.
- Reinstall and tighten the nuts. Tighten to 18 Nm (13 lbf. ft.)
- Reinstall the rubber seals. See point 3.




- Install the liner for the bumper cover. Rivet the liner on both sides
- Reinstall the wheels. Tighten the front wheels. Tighten to 110 Nm (81 lbf. ft).

The control module is positioned on the right-hand body side




- Mark the surfaces for the position of the Velcro strip on the control module and the side of the body
- Clean the marked surfaces using the wet cloth. Allow to dry
- Remove the protective film from the Velcro strip. Secure the strip on the marked surface on the control module
- Remove the protective film from the remaining Velcro strip. Secure on the marked surface on the body side
- Install the control module
- Connect the cable from the sensors.

Connecting the buzzer




- Connect the 16 pin connector to the control module
- Route the control module cable harness as illustrated
- Install the clip (1) on the buzzer (2)
- Connect the 2-pin connector (3) to the cable harness as illustrated
- Install the buzzer at the smaller hole in the left-hand side of the parcel shelf
- Clamp the cable harness along the existing mechanical cable for folding the rear seat. Excess cable must be gathered and secured at the control module
- Also secure the connector.




- Disconnect the green connector (1) from the reversing lamp. Separate the connector
- Remove the black (SB) cable from terminal 1
- 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 cable terminal to terminal 1 in the connector
- Disconnect the blue (BL) cable from terminal 3. Cut off the cable terminal and twin it with the red (R) cable to the control module
- Install a new cable terminal, P/N 9168510. Connect the cable terminal to terminal 3 in the connector
- Reinstall the connector on the reversing lamp.

Switch to shut off the reverse warning system (used when reversing with a trailer for example)




- Place the switch (1) under the parcel shelf at the holes for the buzzer. Drill out the holes. Use a 3.5 mm (1/8") diameter drill bit. Screw the switch into place
- Route the cable beside the cable for the buzzer towards the control module for the reverse warning system and on to the reversing lamp. Secure using tie straps.

Connecting the switch




- Cut off the positive supply (1) to the control module
- Install the cable terminals (2) on the positive supply. Connect to the switch
- Clamp the excess cable.