Part 3

Turn-by-turn Navigation System (Continued)

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 62-64 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 59-61.

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.

Installing the CD drive in the console

- Take the CD drive from the kit. Remove the screw to the adapter and remove the adapter on the side of the CD drive. Do this on both sides. These parts shall not be used again.

Applies to kits with the older version of the CD console
- Take the CD drive console from the kit a drill a -3.5 mm (9/64") hole on each side of the console as illustrated.
- Deburr the hole edges and apply anti-corrosion agent to them.

- Clean the marked surface on the rear edge of the console using isopropanol P/N 1161721. Wipe dry.

- Take a Velcro fastener from the kit and remove the protective tape.

- Press in the Velcro fastener centrally on the rear section of the console. Press hard so that it is firmly secured.

- Take the CD drive from the kit and clean the marked surface on the underside using isopropanol P/N 1161721. Wipe dry.

- Take a Velcro fastener from the kit and remove the protective tape.

- Press in the Velcro fastener in the centre of the rear section of the CD drive. Press hard so that it is firmly secured.

- Insert the CD drive into the console.
- Fit the two screws from the kit in the console and CD drive.
- Press in the rear end of the CD drive against the console so that the Velcro fasteners secure.
- Tighten the CD drive to the console with the two screws.
Applies to cars in Europe: continue with step 79.

Connection to CD drive, applies to cars outside Europe

Applies to cars without towbar from and including model year 2005-

Connect:
- the cable (1) with yellow connector in the routed cable harness to the CD drive, furthest to the left in the connector
- the cable (2) with brown connector in the routed cable harness to the CD drive
- the cable (3) with black connector in the routed cable harness to the CD drive
- the cable (4) from the GPS antenna (a faint click is heard when it is connected) to the CD drive.
White and green/blue connectors in the routed cable harness are only used if the car is to have a TMC receiver. Clamp them up with tie straps from the kit.
- the adapter wiring (5) from the kit with large black and grey connectors, to the socket for towbar wiring in the fuse holder. The existing connector to the towbar wiring in the fuse holder is detached.
- the cable (6) from the towbar wiring to the adapter wiring
- the cable (7) in the routed cable harness to the adapter wiring
The two grey connectors shall not be used. Clamp them up together with all excess cables using a tie strap from the kit, on the left-hand side in the rear edge of the wheel housing in a suitable way, so that there is no rattling.

Applies to cars up to and including model year -2004 Illustration A

- Remove the two screws on the left-hand side in the tailgate sill trim panel.

Illustration B

- Lift the panel. Guide in the long adapter wiring (the two grey individual connectors must be positioned furthest back at the rear crossmember) with the many large connectors from the kit, in the gap between the floor support (1) and the panel (2). Route the connectors to the connector for the towbar wiring in the rear crossmember.
- Insert the cable as far under the panel as possible. Ensure that the cable is not trapped.
- Press the panel into place.
- Reinstall the screws in the panel. Tighten.

Applies to cars without towbar up to and including model year -2004 Illustration A

- the cable (6) in adapter wiring routed earlier to the rear crossmember, to the pre-routed connector for towbar wiring
- the grey connector (7) to the towbar wiring, to the corresponding connector in the routed adapter wiring
The two black connectors shall not be used. Clamp them up together with all excess cables using a tie strap from the kit, on the left-hand side in the rear edge of the wheel housing in a suitable way, so that there is no rattling.
- Clamp up the adapter wiring together with the excess grey connector along the rear crossmember with four tie straps (8) from the kit.

Applies to cars with towbar up to and including model year -2004 Illustration A

- the cable (6) in adapter wiring routed earlier to the rear crossmember to the pre-routed connectors for the towbar wiring.
- pull apart the connectors (7) to the towbar wiring and connect to them the two grey connectors in the adapter wiring
The two black connectors shall not be used. Clamp them up together with all excess cables using a tie strap from the kit, on the left-hand side in the rear edge of the wheel housing in a suitable way, so that there is no rattling.
- Clamp up the adapter wiring along the rear crossmember with four tie straps (8) from the kit.

Installing the TMC receiver, only applies to cars in Europe

- Take the TMC receiver from the kit and clean the marked surface on the underside using isopropanol P/N 1161721. Wipe dry.

- Take two of the long Velcro fasteners from the kit and cut them into four pieces of equal length.

Illustration A

- Remove the protective tape from two of the cut Velcro fasteners.

Illustration B

- Press in the Velcro fasteners on the underside of the TMC receiver, approximately in the positions illustrated.

- Take the two remaining Velcro fasteners.

Note! Do not remove the protective tape.

Press in the Velcro fasteners centred against the Velcro fasteners on the TMC receiver.

- Connect the white connector in the routed cable harness to the TMC receiver.

- Remove the protective tape from the Velcro fasteners.

- Position the TMC receiver on the top of the CD drive as illustrated (rear edge is edge to edge with the rear edge of the CD drive and centred in the middle) and press it in. Press in firmly so that the tape adheres.

- Attach the yellow (1) connector from the screen to the green connector (2) on the routed cable harness.

- Remove all screws in the tailgate sill trim panel.

- Take the solid core wire from the kit and lay it along the tailgate sill trim panel.

Note! The cable end with the angled connector must be on the left-hand side.

- Route the connector to the TMC receiver. The cable must be routed on the underside of the fuse holder along the existing cable harnesses.
- Route the other end of the cable in front of the right-hand tail lamp to the antenna amplifier.
- Carefully pull the tailgate sill trim panel upwards by the outer edges on the right and left-hand sides until a click is heard and the clips release.
- Lift the panel and insert the cable harness (1) in the gap between the floor support (2) and the panel.
- Insert the cable as far under the panel as possible. Ensure that the cable is not trapped.

Applies to cars from and including model year 2005-
- Press the panel into place.
- Reinstall the screws in the panel and tighten them.

- Detach the cable and remove the existing amplifier on the right-hand side of the right rear side member, under the right-hand rear lamp.
- Take the antenna amplifier (1) from the kit. Connect the cable (2) to the connector (3) for the antenna in the rear bumper by the right-hand tail lamp.
- Position the antenna amplifier on the edge of the panel in front of the right tail lamp as illustrated.
- Tighten the antenna amplifier.

- Connect the routed cable to the lower socket (1) on the antenna amplifier.
- Connect the loose cable to the upper socket on the antenna amplifier.
- Applies to cars from and including model year 2005-:
Clamp the cable at the existing cable harness under the tailgate sill panel, with four tie straps (2) from the kit.
- Applies to cars up to and including model year -2004:
The cable to the antenna amplifier is clamped up together with the adapter wiring to the towbar wiring in steps 94-95.

Connection to CD drive and TMC receiver, only applies to cars in Europe

Applies to cars without towbar from and including model year 2005-

Connect:
- the cables (1) with yellow, green and blue connectors in the routed cable harness to the CD drive (yellow connector to the left in the connection)
- the cable (2) with brown connector in the routed cable harness to the CD drive
- the cable (3) with black connector in the routed cable harness to the CD drive
- the cable (4) from the GPS antenna (a faint click is heard when it is connected) to the CD drive
- the cable (5) from the antenna amplifier under the right-hand rear lamp to the TMC receiver
- the cable (6) with large black connector to the socket for towbar wiring in the fuse holder.
- Clamp all excess cable with a tie strap from the kit, on the left-hand side in the rear edge of the wheel housing in a suitable way, so that there is no rattling.

Applies to cars with towbar from and including model year 2005-

Connect:
- the cables (1) with yellow, green and blue connectors in the routed cable harness to the CD drive (yellow connector to the left in the connection)
- the cable (2) with brown connector in the routed cable harness to the CD drive
- the cable (3) with black connector in the routed cable harness to the CD drive
- the cable (4) from the GPS antenna (a faint click is heard when it is connected) to the CD drive
- the cable (5) from the antenna amplifier under the right-hand rear lamp to the TMC receiver
- the adapter wiring (6) from the kit with large black and grey connectors, to the socket for towbar wiring in the fuse holder (existing connector to the towbar wiring in the fuse holder is detached)
- the cable (7) from the towbar wiring to the adapter wiring
- the cable (8) in the routed cable harness to the adapter wiring
The two grey connectors shall not be used. Clamp them up together with all excess cables using a tie strap from the kit, on the left-hand side in the rear edge of the wheel housing in a suitable way, so that there is no rattling.

Applies to cars up to and including model year -2004
- Lift the panel. Guide in the long adapter wiring (the two grey individual connectors must be positioned furthest back at the rear crossmember) with the many large connectors from the kit, in the gap between the floor support (1) and the panel (2). Route the connectors to the connector for the towbar wiring in the rear crossmember.
- Insert the cable as far under the panel as possible. Ensure that the cable is not trapped.

Applies to cars without towbar up to and including model year -2004 Illustration A

Connect:
- the cable (1) with yellow, green and blue connectors in the routed cable harness to the CD drive (yellow connector to the left in the connection)
- the cable (2) with brown connector in the routed cable harness to the CD drive
- the cable (3) with black connector in the routed cable harness to the CD drive
- the cable (4) from the GPS antenna (a faint click is heard when it is connected) to the CD drive
- the cable (5) from the antenna amplifier under the right-hand rear lamp to the TMC receiver
- the cable (6) in the adapter wiring from the kit, with large black and grey connectors, to the corresponding connector in the routed cable harness
- the cable (7) in the adapter wiring routed earlier to the rear crossmember, to the pre-routed connector for the towbar wiring

Illustration B

- the cable (8) with grey connector to the towbar wiring, to the corresponding connector in the routed adapter wiring
The two black connectors shall not be used. Clamp them up together with all excess cables using a tie strap from the kit, on the left-hand side in the rear edge of the wheel housing in a suitable way, so that there is no rattling.
- Clamp up the adapter wiring together with the excess grey connector and cable to the antenna amplifier along the rear crossmember with four tie straps (9) from the kit.
- Press the panel into the tailgate sill.
- Reinstall all of the screws in the panel and tighten it.

Applies to cars with towbar up to and including model year -2004 Illustration A

Connect:
- the cable (1) with yellow, green and blue connectors in the routed cable harness to the CD drive (yellow connector to the left in the connection)
- the cable (2) with brown connector in the routed cable harness to the CD drive
- the cable (3) with black connector in the routed cable harness to the CD drive
- the cable (4) from the GPS antenna (a faint click is heard when it is connected) to the CD drive
- the cable (5) from the antenna amplifier under the right-hand rear lamp to the TMC receiver
- the cable (6) in the adapter wiring from the kit with large black and grey connectors, to the corresponding connector in the routed cable harness
- the cable (7) in the adapter wiring routed earlier to the rear crossmember, to the pre-routed connector for the towbar wiring

Illustration B

- pull apart the connectors (8) to the towbar wiring and connect to them the two grey connectors in the adapter wiring.
The two black connectors shall not be used. Clamp them up together with all excess cables using a tie strap from the kit, on the left-hand side in the rear edge of the wheel housing in a suitable way, so that there is no rattling.
- Clamp up the adapter wiring together with the cable to the antenna amplifier along the rear crossmember with four tie straps (9) from the kit.
- Press the panel into the tailgate sill.
- Reinstall all of the screws in the panel and tighten it.

Installing the CD drive

- Screw in the CD drive with console above the left-hand rear wheel housing with three screws (1) from the kit, two are secured in the console.

Note! Make sure that no cables are trapped.

- Tighten the screws. Tighten to 10 Nm (7.5 lbf ft).
- Clamp up the cables behind the CD drive with tie straps from the kit.

- Take the new insulation panel from the kit and fit it above the CD drive and brackets to the fuse holder. On cars with TMC receiver the punched out cover may need cutting further in the edges so that the unit has space.
- Install the insulation panel with the clip (1) from the kit.
- Reinstall the fuse holder.

Finishing work

- Install a new side panel and cover to the CD drive, and new folding panel from the kit in the cargo compartment.
- Reinstall the sill trim panels on the left-hand side.
- Reinstall the side cushion.
- Fold the backrest back into place.
- Reinstall the seat cushion.
- Newer cars:Connect the connectors to the radio, the dashboard environment panel and to the keypad to the telephone if fitted. Reinstall the unit with radio and dashboard environment panel in the centre console. Tighten with the two screws.
- Older cars: Connect the connector to the radio, and if the car has a telephone, to its keypad. Reinstall the radio. Connect the connectors to the dashboard environment panel and reinstall it.
- Reinstall the panel and gear selector lever boot around the gear selector lever.
- Reinstall the soundproofing panel on the left-hand side.
- Reinstall the centre console side panel.
- Check that the following fuses and relays are installed in the Rear Electronic Module (REM):

- Take a new loudspeaker grille from the kit and press it into the dashboard.

- Take the screen from the kit and press it into its holder/connector.

- Take the remote control from the kit, fit batteries and press it into the holder, if fitted.

- Turn the ignition key to position II.
- Reconnect the battery negative lead.
- Reinstall the storage box.
- Reinstall the floor hatches.
- Reinstall the cargo compartment carpet.

Programming the system

Illustration A

Program the system as follows:

Main menu
1. Select "Settings"
2. Select "Service"
3. Press OK at "Code"
4. Enter code:
- 6330
1. Select "X-Code"
2. Enter code:
- XCA9 - VQ3Z
A6SV - FWY1
1. Press "OK"
2. Press "Save settings"

Note! Do not forget this!

Illustration B

Volvo menu
- The system now starts up with the Volvo logo and is ready for use.

Applies only if the car has AEM and the Radio Mute function is desired
The function mutes the radio when there are navigation messages.
- Take a new cable with minimum area 0.35 mm² (0.000542501 in²).
- Using a crimping sleeve, splice the new cable with the brown/white (BN/W) cable from the brown connector at the navigation unit.
- Route the cable along the rear crossmember and connect it at position 11 in AEM. If the position is in use by handsfree mute, splice the cable with the crimping sleeve. Make sure that the splices are done as described in steps 59-61.
- Load the Telemute application in AEM.