Part 1
Turn-by-turn Navigation System
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.
Turn-by-turn Navigation System
Note! The holder for the remote control can only be fitted on cars without hands-free telephone.
Preparations, dashboard
- Move the left front seat to its rearmost position
- Turn the ignition switch to position 0.
- Disconnect the battery negative lead.
Note! Wait at least five minutes before disassembling the connectors or removing other electrical equipment.
Illustration A
- Remove the loudspeaker grille as follows:
Insert the tool, Volvo P/N 999-5919-46 in the joint between the loudspeaker grille and the dashboard approximately as illustrated, until it engages.
- Twist the tool 90° so that the bent section engages with the underneath of the loudspeaker grille.
Illustration B
- Pull upwards until the loudspeaker grille detaches. The loudspeaker grille is securely fastened by five clips. Move the tool closer to the clips to facilitate removal.
Note! Do not damage the dashboard.
- Remove the screws (1). Remove the bracket (2).
Applies to cars with centre loudspeakers
- Remove the three screws in the speaker (1).
- Lift up the loudspeaker. Disconnect the connector (2).
- Place the loudspeaker to one side, it shall not be used again.
- Detach the panel (1) with the gear selector lever boot using a weatherstrip tool.
- Move the gear selector lever to its rearmost position.
- Pull the panel (1) with boot rearward and turn as illustrated.
- Remove the screws (2) from the dashboard environment panel.
- Angle the dashboard environment panel outwards so that it is possible to insert a couple of fingers between the centre console and the reverse of the panel.
- Detach the dashboard environment panel by pulling it downwards while maintaining the same angle. Some force is required because the panel is tightly installed.
- Disconnect the connectors on the reverse of the dashboard environment panel. Place the dashboard environment panel to one side.
Note! If any of the outer hooks break off, these must be repaired.
- Remove the screws from the radio bracket.
- Pull out the bracket with the radio. Pull the lower corner while pressing downwards.
- Detach the connectors from the radio and from the keypad to the telephone if fitted. Place the console with the radio to one side.
Installing the remote control holder
Steps 9 - 13 only apply to cars without hands-free telephone.
- Mark out for drilling holes in the bracket in accordance with the diagram and drill them out with a -3.5 mm (9/64") drill bit.
- File down the edges of the holes.
- Remove the decor strip on the dashboard by carefully pulling the strip straight out, as close to the mounting point (1) as possible.
- Press in the clips so that the ventilation grille is released.
- Remove the grille by prizing with a weatherstrip tool for example.
- Remove the connector (1) for the hazard warning flashers.
- Mark out the holes for the bracket (1) by aligning the edge of the holder to the edge of the hole (2). Press the holder up 3 mm (7/64") and drill holes with a -5 mm (13/64")drill bit. Use a -20 mm (3/4") drill stop.
- Install the holder in the panel and guide the plate (3) through the hole for the ventilator. Screw in the holder and plate with the two screws from the kit.
- Reinstall the decor strip.
- Take the holder for the remote control and tighten it to the bracket in the drilled holes with short screws and nuts from the kit.
Preparations, passenger compartment
- Remove the side panel (1) on the centre console. First twist the clip at the rear edge of the panel a 1/4 turn. Pull the rear edge of the panel outwards and backwards.
- Remove the sill trim panel (2).
- Remove the soundproofing panel on the left-hand side by first removing the two screws and then prying it loose at the back edge with a weatherstrip tool. It is fitted with two clips at the rear edge.
- Remove the rear seat cushion (1) by pulling it up at the front edge, pulling it forward and then lifting it away.
- Remove the sill trim panel at the left rear door.
- Take the seat belts out of the guide (1) on the right and left side cushion.
- Put your hand into the side of the lower section of the left and right-hand side cushions. Release the catches and lift the cushions at the same time. Place the cushions to one side.
- Fold both backrests forward.
- Carefully lift the front edge of the parcel shelf until the clips (1) release.
- Raise the parcel shelf more until the guide pins (2) disengage from their holes.
- Pull out the parcel shelf and lay it on the folded backrests.
Preparations, cargo compartment
- Lift out the cargo compartment carpet.
- Press the centre of the clip at the bottom of the left folding side panel. Press the clip until a click is heard.
- Remove the two clips.
- Remove the plastic nut from the front edge of the side panel.
- Repeat the operation on the right-hand side.
- Turn the handle (1) on the right and left-hand sides. Turn the handle through 90°.
- Lower the side panels and lift them out. Put the left side panel to the side (there is a new one in the kit).
- Remove the two covers (2) and screws (3) in the sill trim panel.
- Hold the outer edges (4) of the sill trim panel and pull in toward the centre so that the clips release from the sides.
- Unplug the connectors (5) of the cargo compartment lamps.
- Remove the sill trim panel. Pull the sill trim panel straight upwards so that the clips release from the rear cross member.
- Remove the clips (1) and plastic nut from the left front side panel in the cargo compartment. The front upper clip is most easily removed from the rear seat side.
- Remove the front side panel.
Installing the screen holder and centre loudspeaker
- Take the holder for the screen from the kit and cut away the attached washer. It shall be used in step 26.
- File away the burrs on the washer and holder.
- Take the cable with yellow and large black connector to the screen from the kit. Thread the cable through the hole in the screen's holder.
- Fit the large connector to the screen's holder.
- Take the washer for mounting the screen's holder to the bracket and fit it on the underside of the holder.
- Take two screws from the kit and tighten the connector to the holder.
- Take the console which secures the complete unit in the dashboard from the kit. Align the screen's holder in the console and attach it with a screw from the kit. Do not tighten hard yet.
- Take the loudspeaker from the kit. Install the loudspeaker in the console together with the screen's holder with screws from the kit. The loudspeaker must be aligned with the cable connectors to the right in the car.
- Tighten all screws to the loudspeaker and holder.
- Align the screen with console and cable at the hole for the centre loudspeaker.
- Guide the free connector down through the hole to the centre loudspeaker, along the left-hand inside of the centre console, along the air ducts under the floor carpet and out at the sill to the left-hand front door.
- Take the remaining long cable harness from the kit and route it the same way as above, but start by guiding it up by the sill under the carpet at the left-hand front door, with the two grey connectors and relay first.
- Clamp both cable harnesses at the existing cable harness, at point (1) and at the strut (2) in the centre console. Use tie straps from the kit.
- Connect the routed cable harness with the two grey connectors and relay as follows:
- The grey connector (1) in the routed cable harness to the corresponding connector (2) in the cable to the centre loudspeaker.
- The grey connector (3) in the routed cable harness to the connector (4) in the cable on the centre loudspeaker.
- Install the complete unit in the hole in the dashboard with the existing screws.
Note! Make sure that the relay and cables are not trapped.
Cable routing
- Route the two cables under the carpet, along the left-hand side of the car, to the rear door.
- Route the cable further under and along the front cable duct (1). Continue along the right-hand side of the rear cable duct (2). On the large cable harness is a black/white (SB/W) solid core wire connected to one of the large connectors. This shall subsequently be connected to the relay box on the left-hand side in the bulkhead.
- Securely clamp the cables at the cable duct with tie strap (3) from the kit.
Illustration A applies to cars up to and including model year -2004
Illustration B applies to cars from model year 2005-
- Route the two cables under the carpet, along the left-hand side of the car, to the rear door.
- Route the cable further under and along the front cable duct (1). Continue along the right-hand side of the rear cable duct (2).
On the large cable harness is a black/white (SB/W) solid core wire connected to one of the large connectors. This shall subsequently be connected to the relay box on the left-hand side in the bulkhead.
- Securely clamp the cables at the cable duct with tie strap (3) from the kit.
Connection to the relay box
- Remove the screw in the panel to the bonnet release and remove the bonnet release from the side of the body.
- Thread the bonnet release through the hole in the carpet and fold the carpet away from the side of the body.
- Position the edge of the carpet under the pedals.
- Pull forward the black/white (SB/W) solid core wire routed earlier and position it as illustrated.
Steps 36 - 39 apply to cars of model year 2005-
- Remove the 60-pin black connector from the rear side/underneath of the relay box on the left-hand side under the dashboard. First press in the release button at the blue catch, following which turn the catch as far as possible until the connector releases.
- Remove the connector from the holder by carefully prizing out the two catches at the sides, and then press out the connector.
Connection in connector
- Install the cable terminal P/N 9442486 from the kit on the routed black/white (SB/W) solid core wire.
- Connect the black/white (SB/W) solid core wire to position 59 in the connector. The positions are marked with small figures on end faces of the connector.
- Reinstall the connector in the holder and install the connector in the relay box.
- Fold back the carpet. Reinstall the bonnet release and tighten it with the screw.
The connection in the connector at position 59 is in use by another cable
- Undo and cut the cable in position 59 a bit from the connector so that the new cable can be spliced together with this one using a crimping sleeve.
- Splice the leads as illustrated in steps 40 - 42.
- Reinstall the connector in the holder and reinstall the connector in the relay box.
- Fold back the carpet.
- Reinstall the bonnet release and tighten it with the screw.
Splicing with insulated, water-resistant splicing sleeve
Illustration A
Select a suitable splicing sleeve based on the area of the cable. See table.
If the area of the cables differs so greatly in size that they do not fit the same splicing sleeve, select the splicing sleeve that fits the thicker of the cables.
- Strip the thicker cable. See table.
- Strip the thinner cable to double the length and double over the stripped section.
Illustration B
- Strip the three cable ends in accordance with the above table. Use stripping pliers, P/N 9512620.
Pressing the sleeve
Illustration A
- Insert the crimping sleeve, P/N 9130467, in the press tool, P/N 9512785. Select a socket based on the colour marking. Clamp the pliers just enough that the crimping sleeve remains in the pliers.
- Insert the cable in the crimping sleeve until it reaches the stop.
Note! Make sure that the cable insulation does not come into the press area of the sleeve or that the stripped part or the cable extends outside of the sleeve.
Illustrations B and C
- Press the legs of the pliers completely together to ensure a proper splice. The pliers will then release automatically.
- With your hand, check that the crimping sleeve is securely in place.
Heating the crimping sleeve
Illustrations A and B
- Place a suitable shield behind the cables to be crimped to prevent thermal stress to the surrounding area.
- Warm the sleeve with a hot air gun, P/N 9512777, and suitable nozzle. It is extremely important that the crimping sleeve be securely crimped around the cable. You should be able to see that a little bit of glue has been forced out around the cable. (Illustration B).
Steps 43 - 45 apply to cars up to and including model year -2004
- Insert a screwdriver up between the bracket and relay box. Turn the screwdriver so that the bracket expands. At the same time pull the bracket out towards the lower edge of the dashboard.
- Remove the relay box from the bracket and pull it down under the dashboard.
- Undo the screw holding the connector so that it releases from the threads. Feel with your fingers to release the screw.
Caution! Take care not to damage the terminal pins.
- Detach the connector using pliers. Grip the screw and pull it straight out so that the connector and cover follow too.
- Undo and cut the cable in position D10 a bit from the connector so that the new cable can be spliced together with this one using a crimping sleeve.
- Splice with an insulated, water-resistant splicing sleeve as in steps 40 - 42.
Reinstall:
- the connector
- the cover on the connector
- the connectors to the relay box and tighten the screw
- the relay box.
- Fold back the carpet. Reinstall the bonnet release and tighten it with the screw.