Part 1

Remote start, electric engine block heater




















































INTRODUCTION
- NOTE! Read through the whole installation instruction before starting the work.
- The illustrations display the procedure in order of operation. The order of operation is repeated in the text section






Cars equipped with SRS/SIPS (Airbag)

Warning! Extra care must be taken when working on cars equipped with SRS/SIPS air bags. This is important to prevent:1. Personal injury2. Damage to or malfunction of the SRS/SIPS system. Work on the SRS/SIPS systems or related components must always be carried out by an authorized Volvo workshop.

Is the car equipped with SRS (supplemental restraint system)?
Cars equipped with a driver's airbag have the letters "SRS" imprinted on the centre panel of the steering wheel. Cars equipped with driver's and passenger airbags are marked with "SRS" on both the steering wheel centre panel and also on the dashboard close to the airbag.
If the car is equipped with SIPS (side impact protection system ) a "SIPS" decal is marked on both the front seats.
Cars equipped with inflatable curtains have the marking "SRS" on one of the panels along the posts on the inside of the car.
Cars equipped with SRS (supplemental restraint system) also have an "SRS" decal on the front windscreen.

Warning! The air bag inflation areas must not be obstructed. Never place any objects, such as upholstery or accessories, within these areas. The panels must be able to open in the correct manner at the right time, otherwise there is an increased risk of personal injury in the event of a collision.

Do not damage the SRS wiring!
Do not trap, chafe, pierce or damage the SRS wiring. SRS wiring has orange casing and/or is plaited.

Steering and front suspension
The contact reel in the SRS system can easily be damaged when working on the steering wheel, steering shaft or steering gear. Refer to the SRS (supplemental restraint system) or service instructions in VIDA for information on carrying out such work. This is to prevent damage.

SRS warning lamp
If the SRS warning lamp lights after repairs have been carried out, take the car to an authorized Volvo workshop.






Supplemental restraint system module, SRS

C30/S40(04-)/V50/S60/XC60/C70(06-)/V70/XC70/S80/XC90
The supplemental restraint system module (SRS) is located on the tunnel under the centre console, in front of the parking brake.






Warning! The ignition must be in position "0" and the key removed from the ignition switch if any connector in the SRS system is to be unplugged. Then wait at least three minutes and disconnect the battery negative lead before unplugging any of the connectors. When work is completed, the ignition key must be turned to position "II" before reconnecting the battery negative lead.






Remote start, electric engine block heater




- Turn the ignition switch to position 0.
- Disconnect the battery negative lead.

Note! Wait at least three minutes before unplugging the connectors or removing other electrical equipment.

Steps 2-12 apply to the S60/V70/XC70 and S80





Only applies to cars with air baffles for the brakes
- Raise the car.
- Remove the screw (1) in the left air baffle (2) for the front brake.
- Remove the left-hand air baffle by pulling it backwards.
- Remove the right-hand air baffle in the same way.




- Remove the middle air baffle (1) by first removing the screws (2). Then depress the catches (3) and pull the baffle back.
- Remove the engine splash guard (4) by first removing the screws (5).




- Drill holes for the timer relay in the lower side/front edge of the left-hand front member using a -4 mm (5/32") drill bit.
- Treat the edges of the holes using a rust-proofing agent.




- Install the relay with new screws, on the underneath of the front member.




- Remove the locking sleeve from above the existing cable splice and pull off the cable from the engine block heater's cable.
- Cut off the clips holding the engine block heater's cable at the subframe and pull it off.
- Remove the old clips from the subframe.
- Remove the cable from the subframe.




- Move the front socket cable (1) up on the left-hand side of the left-hand side member. Then insert it in the upper side of the side member, under the left-hand headlamp, and pull it along the right-hand side of the side member.

Note! Ensure that the washer hose is not trapped. Lubricate the connector o-rings using low temperature grease, part no. 1161427.

- Securely press the cable into the connection on the front edge of the relay and press a new locking sleeve over the splice.
- Route the new cable splice (2), L = 1400 mm (47 15/64"), on top of the subframe's left-hand front corner and connect it to the rear connection on the relay, allow it to hang down.
- Press the cable into place securely and press the smaller locking sleeve over the splice.
- Connect the ground cable to the existing ground terminal with new screw and toothed washer underneath.
- Route the long cable on top of the subframe's left-hand front corner together with the cable for the engine block heater, allow it to hang.




- Roll up and clamp the excess cable for the front socket using two new tie straps on the reverse of the left-hand side of the bumper as illustrated.




- Press the news clips into the subframe in place of the removed clips.
- Place the cables in the clamps - do not tighten them yet.
- Lubricate the o-ring on the thicker cable connector using low temperature grease, part no. 1161427.
- Connect the thicker cable to the heater cable. Press the cable securely and press a new locking sleeve over the splice.
- Separate the cables evenly in the clamps and tighten.
- Clamp the two cables to each other as illustrated, use two new tie straps.
- Clamp the routed cable together with the cable for the engine block heater. Use six new tie straps along the subframe.




- Remove the centre console's right-hand side panel (1) by turning the clip in the rear edge 45°. Pull the panel out at the rear edge and then straight back.
- Remove the sound barrier (2) by first removing the three screws (3). Prize it away from the three clips on the rear and pull the panel backwards.
- Remove the panel (4) in the right-hand front door sill by pulling it away backwards at its top and front edges. Following which, pull the panel up so that all the clips detach.





Applies to cars with a passenger compartment connector socket
- Fold aside the carpet at the right-hand front seat to access the grommet in the engine compartment. It is slightly to the left in the lower edge of the sound proofing.
- Remove the locking sleeve between the cable and passenger compartment connector socket.
- Push out the cable to the engine compartment.
- Detach the rubber grommet from the cable.
- Cut off the larger top of the rubber grommet.
- Install the cable in the grommet.
- Reinsert the cable into the passenger compartment.
- Connect the cable to the passenger compartment connector socket and press the sleeve over the splice.
- Press the rubber grommet into place.





Applies to cars without a passenger compartment connector socket
- Cut off the pre-punched engine insulation.
- Remove the rubber grommet that is in front of the insulation.
- Insert the new cable in the lead-in hole to the passenger compartment and press the rubber grommet, positioned on the cable, into the hole.

Steps 13-37 apply to the XC90




- Detach the left-hand headlamp by pulling up the two locking pins and then carefully pulling away the headlamp forwards.




- Carefully prize up the catch on the connector for the headlamp using a screwdriver.
- Pull the catch up completely, detach the connector and place the headlamp to one side.





Applies to cars with V8 engine
- Remove the branch connector with the cables from the underside of the plate beneath the headlamp. Remove the screw, nut and washer (1) and tie strap (2), and pull the branch connector forward.





Applies to cars with 5 and 6-cylinder engines
- Remove the branch connector with the cables from the underside of the plate beneath the headlamp by removing the screw and the nut (1).
- Cut away the tie strap (2).





Applies to all models
- Remove the locking sleeves over the joints on the branch connector and pull the cables away from it.
- Place the branch connector to one side, it shall not be re-used.





Applies to all models
- Take the relay with cable from the kit.
- Grease the O-ring on the connector for the front socket and both connectors on the relay using low temperature grease, part no. 1161417-9.

Note! Do not get any grease on the surfaces of the connector.





Applies to all models
- Connect the cable (1) from the front socket to the relay.
- Connect the cables to the engine block heater and passenger compartment connector socket to either of the sockets (2) or (3) on the relay and press them in firmly.





Applies to cars with V8 engine
- Take three locking sleeves from the kit and press them in over the cable joints.





Applies to cars with 5 and 6-cylinder engines
- Take three locking sleeves from the kit and press them in over the cable joints.
- Take a tie strap (1) from the kit and clamp the electrical cable securely with the ground cable to one of the cables for the engine block heater/passenger compartment connector socket.





Applies to cars with V8 engine
- Take the relay with cables and fit it on the underside of the plate beneath the headlamp. Fit the relay with the side against the plate that allows the connector to be accessible.
- Take a screw, washer and nut (1) from the kit. Tighten the relay to the plate.
- Guide the relay's ground cable (2) down on the left-hand side of the side member.
- The long thin cable (3) from the relay is routed in the same direction as the cable for the heater and passenger compartment socket.
- Clamp the ground cable with the cable to the front socket using a tie strap from the kit.





Applies to cars with 5 and 6-cylinder engines
- Take the relay with cables and place it on the underside of the plate (1). Fit the relay with the side against the plate that allows the connector to be accessible.
- Take a screw, washer and nut (2) from the kit. Tighten the relay to the plate.
- Clamp the cable for the front socket at point (3) in the plastic eye for the bumper cover's mounting.
- Guide the thin cable with the ground cable from the relay down to the same location as the cables for the engine block heater/passenger compartment connector socket.
- Clamp all cables together at point (4) with a tie strap from the kit.