Accessory Electronic Module Tailored Reversing Warning System

Accessory Electronic Module tailored reversing warning system

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

Preparations, cargo compartment

- Turn the ignition key to position 0
- Remove the ignition key from the ignition lock. (Does not apply to cars with automatic gearboxes.).




- Detach the cargo compartment carpet at the rear edge (turn the two handles (1) a quarter turn).




- Fold up the front edge of the cargo compartment carpet. Fold the front half back over the rear half of the carpet.




- Slide the entire cargo compartment carpet forward slightly. Twist slightly to remove the carpet through the tailgate opening
- Remove the cargo compartment carpet.




- Press the centres of the clips until a click is heard. Remove the clips
- Remove the plastic nut
- Repeat the operation on the other side.




- Turn the catch (1) a quarter of a turn
- Fold the side panels on the left and right-hand sides of the cargo compartment inwards. Remove the side panels
- Pull the tailgate sill trim panel (2) forwards on the right and left hand sides until the two clips on each side release. Carefully pull the panel with some force as it is tightly secured
- Remove the wiring (3) for the cargo compartment lighting
- Pull the sill trim panel straight up until the four clips on the underside release. Remove the sill trim panel.





Remove:
- the two nuts from the front edge of the battery holder and the screw from the rear edge
- the battery holder
- the cover
- the battery negative lead
- the battery, or move the battery to facilitate access.

Removing the rear bumper




- Slacken off the screw (1) almost completely in the rear edge of the wheel arch on the left and right hand sides
- Press the screw using a screwdriver. This is so that the loose ends on the inside of the bumper cover bend backwards
- Carefully drill out the rivets (2) underneath the bumper on both sides. Use a - 6 mm (1/4") drill bit. Do not damage any of the plastic components.





Remove:
- the perforated sections of the insulation panel (1) and the nuts (2) for the bumper in the rear cross member
- the antenna connector (3)
- the rubber seal (4) covering the hole over the antenna connector. Save the seal as it will be used to lead-in the cable harness for the sensors in the existing hole.




- Pull the bumper backwards slightly. Bend out the sides (1) so that they detach from the mountings (2). 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. Use a mild soap solution
- Install the backing paper evenly distributed over the bumper.

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

Installing the sensors





Remove:
- the four mountings (1) in the upper edge of the bumper cover on the left and right-hand sides
- the ten catches (2) from the upper edge of the bumper cover
- the eight catches (3) in the upper edge of the bumper cover
- the seven catches (3) from the lower edge of the bumper cover.




- Find the four hole markings, they are positioned according to the distances in the illustration.




- Pre drill the four holes from the inside. Use a - 3 mm (1/8") diameter drill bit
- Drill out the holes. Use a - 9 mm (3/8") diameter drill bit.




- Enlarge the holes in the bumper casing. Use a - 31 mm (1 7/32") diameter hole cutter.




- Wash any dirt and stones off the bumper casing. Use a mild soap solution
- Clean around the drilled holes. Use a cleaning pad (P/N 9192678). Allow to dry
- Apply primer (P/N 9192679) around the holes. Allow to dry.

Note! It is important that primer is used otherwise the sensor holders will not mount securely in the bumper cover.




- Clean the mating surface on the sensor holders. Use cleaning pad (P/N 9192678). Allow to dry
- Apply the primer (P/N 9192679) on the cleaned surfaces of the sensor holder. Allow to dry.




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




- Remove the protective film from the orange pieces of tape on the sensor 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! The tape adheres immediately.

Caution! Incorrect positioning of the sensors may result in partial or complete malfunction.




- 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.




- Clean the inside (1) of the bumper cover where the cable harness is to be secured. Use primer (P/N 9192679) on the cleaned surfaces.




- Cut out a recess (1) in the right hand inside of the foam to make room for the cable harness for the sensors
- Reinstall the foam in the bumper cover.




- Secure the cable harness at the embossing in the top edge of the bumper casing, and at the foam on the right-hand side. Use pieces of butyl tape (1) over the primed surfaces.




- Remove the sections of the bumper rail reinforcements on the right-hand side to make room for the cable harness for the sensors. See the illustration.




- Mark out for drilling on the outside of the right hand side of the bumper rail to make holes for the cable harness for the sensors
- Drill out the hole. Use a - 27 mm (1 1/16") diameter hole saw
- File the hole edges.




Make a cut out in the plates on the left and right hand sides in the bumper rail to make room for the outer sensors.

Right-hand side:
- Cut out one plate (1) as illustrated.

Left-hand side:
- Cut out both plates (2).




- Place the bumper rail in the bumper cover above the foam rubber. At the same time route the cable harness (1) through the hole (2) in the bumper rail
- Reinstall the antenna connector (3) in the bumper rail
- Check that the outer sensors are unimpeded by the bumper rail. If not, cut further
- Press the bumper rail into place in the foam in the bumper cover. Ensure that the hooks have engaged. Secure all the catches in the top edge of the bumper.




- Cut off the rubber bushing (1)
- Lift the bumper into position
- Route the cable harness for the sensors through the hole in the outer panel for the rear cross member
- Route the cable harness in the gap between the inner and outer panel for the cross member towards the right. Continue out through the round hole (positioned above the hole for the connector for the antenna cable) under the right tail lamp
- Take the rubber seal previously removed. Cut the rubber seal as illustrated
- Press the rubber seal into the rear cross member, around the cable harness for the sensors.

Installing the rear bumper




- If the mountings (1) have released from the rear edge of the wheel arch, reinstall them: press the mountings fully into the grooves. Screw the screw in a few turns
- Reinstall the bumper by pressing it forwards. Ensure that the four screws protruding from the bumper align in the holes on the car
- Before the bumper is completely installed, slide the top edge (2) into the grooves. Then slide the bumper fully in.




- Tighten the screw (1) on both sides
- Rivet (2) the bumper on the underneath on both sides as illustrated
- Reinstall the bumper nuts. Tighten the nuts. Tighten to 18 Nm (14 lbf.ft)
- Install the rubber seals to cover the four nut holes
- Reinstall the antenna connector.

Installing the cable harness and control module




- Clean the panel profile (1) under the right-hand tail lamp, where the Velcro strap is to be secured. Use a wet cloth and allow to dry.
Position the Velcro strap so that the control module is unimpeded by the hatch
- Clean the corresponding surfaces on the reverse of the control module. Use a wet cloth. Allow to dry
- Apply primer (P/N 9192679) to the cleaned surfaces. Allow to dry.
A. Remove the protective film from two of the Velcro straps of the same type.
B. Press the two Velcro straps into place on the reverse of the control module.
C. Press the two other Velcro straps onto the newly installed Velcro straps on the control module. Remove the protective film.
Locate the control module on the profile under the right hand tail lamp, as illustrated. Press the control module firmly into place.
- Connect the cable harness with the 16-pin connector (from the kit) to the control module
- Connect the cable harness for the sensors to the control module.




- Slacken off the screw (1) and the nut (1) a few turns in the lock facing for the rear Accessory Electronic Module for the right rear wheel well
- Pull the lock facing out to the right. Remove the lock facing.




- Lift the Accessory Electronic Module from the bracket by the right-hand rear wheel well.




- Disconnect the large connector from the Accessory Electronic Module. First press in catch (A). Pull the black locking handle (B) in the direction of the arrow until a click is heard. Disconnect the connector Remove the connector from the control module.





Remove:
- the black catch holding the black switch in place in the connector by pulling in the direction of the arrow
- the black switch by inserting a pointed object in the hole in the other end. Press the switch out.




- Connect the small cable harness from the control module to the connector for the accessory electronic module as follows:
- Red (R) cable to terminal 6
- Blue (BL) cable to terminal 7
- Black (BLK) cable to terminal 8.

Note! The numerical markings can be found on the top and bottom of the black switch. However, the markings are extremely small so be careful when installing the three cables.




- Reinstall the black switch in the connector. Press the lock into place with the catch
- Press the connector into the Accessory Electronic module. Secure using the black arm
- Reinstall the Accessory Electronic Module. Secure any excess wiring
- Reinstall the lock facing above the Accessory Electronic Module. Tighten the screw and the nut. Tighten to 10 Nm (8 lbf.ft.).

- Clean the visible surfaces on the sensor holders and sensors. Use a wet cloth (P/N 9192678). Allow to dry
- Apply a thin layer of primer (P/N 9192679) 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 as the car.

Note! Use a Volvo recommended paint. Apply a maximum of two layers of paint.

Caution! Too many layers of paint may result in partial or complete malfunction.Unpainted areas may damage the sensors.

Finishing work

Reinstall:
- the battery if removed. Connect the battery, "+" terminal first and then the "-" terminal
- the battery cover and holder
- the sill trim panel for the rear cross member. Connect the cargo compartment lighting
- the two folding side panels
- the cargo compartment carpet.