Relay for the electrical engine block heater. Relay for the electrical engine block heater V1.0

Transcription

1 Installation instructions, accessories Instruction No Version 1.0 Part. No. Relay for the electrical engine block heater Volvo Car Corporation Relay for the electrical engine block heater V1.0 Side 1 / 21

2 Equipment A A A A D Side 2 / 21

3 M Side 3 / 21

4 M Side 4 / 21

5 M Onko sinulla huomautettavaa tästä julkaisusta? Ota yhteyttä lähimpään piirimyyjään. Kiitos! Julkaisun numero: MA , Painos: Huomautukset: Lähettäjä:... Osoite:... Puhelin:... Faksi:... Side 5 / 21

6 INTRODUCTION Read through all of the instructions before starting installation. Notifications and warning texts are for your safety and to minimise the risk of something breaking during installation. Ensure that all tools stated in the instructions are available before starting installation. Certain steps in the instructions are only presented in the form of images. Explanatory text is also given for more complicated steps. In the event of any problems with the instructions or the accessory, contact your local Volvo dealer. 1 Note! This accessory requires software unique to the car. Turn the ignition key to position 0. Applies to cars with manual transmission: Remove the ignition key. Disconnect the battery's minus cable. Note! A Wait at least five minutes before dismantling connectors or removing other electrical equipment. Side 6 / 21

7 2 Only applies to cars with air baffle for brakes Raise the car. Remove the screw (1) in the left air baffle (2) for the front brake. Remove the left air baffle by pulling it backward. Remove the right air baffle in the same way. D Remove the middle air baffle (1) by first removing the screws (2). Then press in the catches (3) and pull it loose backward. Remove the engine protection plate (4) by first removing the screws (5). D Drill hole for the relay in the left front member's underside/leading edge with a Ø 4 mm (5/32 "). Rustproof the hole edges. M Side 7 / 21

8 5 Tighten down new relay and new screw on the underside of the front member as shown. M Remove the lock sleeve over the existing cable junction and pull loose the cable from the engine heater's cable. Cut away the clips that hold the engine heater's cable to the subframe and pull it loose. Remove the old clips from the sub-frame. Remove the cable from the sub-frame. D Route the front inlet's cable (1) on the left side of the left side member. Then route it in on the top of the side member under the left headlight and route it down on the right side of the side member. Note! Make sure that the washer hose is not trapped. Lubricate the connectors' O-rings with low-temperature grease, part no Press the cable securely into the connection on the leading edge of the relay and press a new lock sleeve over the joint. M Route the new junction cable (2), L= 1400 mm (47 15/64"), on top of the sub-frame's left front corner and connect it to the rear Side 8 / 21

9 connection on the relay, let it hang down. Press the cable into place and press the smaller lock sleeve over the joint. Connect the ground cable to existing grounding point with new screw and tag washer, tag washer first. Route the long cable on top of the sub-frame's left front corner together with the cable for the engine heater, let it hang down. 8 The extra part of the cable for the front inlet is rolled up and clamped with two new cable ties on the back of the bumper's left side as shown. M Press the new clips into the sub-frame instead of the ones that were removed. Place the cables in the clamps - do not tighten yet. Lubricate the O-ring on the thick cable's contact with lowtemperature grease, part no Connect the thick cable to the heater's cable. Press it into place securely and press a new lock sleeve over the joint. Distribute the cables evenly in the clamps and tighten. Clamp the two cables to each other as shown, use two new cable ties D Clamp the routed cable together with the cable for the engine heater, with six new cable ties, along the sub-frame. Side 9 / 21

10 10 Remove the tunnel console's right side panel (1) by turning the clip at the trailing edge 45º. Pull the panel outward at the trailing edge and then straight back. Remove the sound wall (2) by first removing the three screws (3). Then bend loose the panel from the three clips on the back, and pull the panel backward. Remove the panel (4) in the right door sill front by pulling it loose backward at its top edge and leading edge. Then pull the panel upward so that all clips release. R Applies to cars where passenger compartment contact is installed Fold aside the mat in the right front seat to access the leadthrough in the engine compartment, it is located slightly to the left at the bottom edge of the sound wall. Remove the lock sleeve between the cable and passenger compartment contact. Route the cable into the engine compartment. Remove the rubber leadthrough from the cable. Cut off the bigger top from the rubber leadthrough. D Install the cable in the leadthrough. Reroute the cable to the passenger compartment. Connect the cable to the passenger compartment contact and press the sleeve over the joint. Press the rubber leadthrough into place. Side 10 / 21

11 12 Applies to cars without passenger compartment contact Cut off the pre-punched engine compartment insulation. Remove the rubber leadthrough located inside of the insulation. Insert the new cable in the leadthrough hole to the passenger compartment and press the rubber leadthrough, located on the cable, into the hole. D Applies to S60 Remove the seat cushion (1) by pulling it up in the leading edge, pull it forward and lift it out. Fold forward the right rear backrest. M Applies to V70 (00-) Fold forward the right rear seat cushion. M Side 11 / 21

12 15 Applies to S80 Remove the seat cushion (1) in the backseat by pulling it straight up at the leading edge on both sides and then forward. If the seat cushion is stuck, pull it up a little at the trailing edge at the same time. D Applies to S80 Fold forward the backrest. A Applies to S80 Remove the right side cushion by inserting your hand at the lower part of the side cushion. Release the catch and lift the cushion at the same time. Place the cushion aside. A Side 12 / 21

13 18 Remove the panel in right door sill rear by first pulling it up at the trailing edge so that the clip releases and then continue pulling it up forward so that the remaining two clips release. M Applies to V70 (00-) Fold forward the right rear backrest. M Side 13 / 21

14 20 Applies to V70 (00-) Remove the right side cushion by first pulling it forward at the leading edge and then lifting it upward. A Applies to V70 (00-) Remove both floor hatches by lifting them slightly at the trailing edge and then pulling them up from their mountings. M Applies to V70 (00-) Remove the foldable panel on the luggage compartment's right side. M Side 14 / 21

15 23 Applies to V70 (00-) Remove the loose insulation mat from the luggage compartment. M Applies to V70 (00-) Remove the right side panel by first removing the cover and the screw at the leading edge. Pull out the panel at the top edge, so that the clip releases. Fold in the panel and lift it out. M Applies to S60 Loosen the luggage compartment mat at the trailing edge by turning the two handles (1) 90º. M Side 15 / 21

16 26 Applies to S60 Pull up the luggage compartment mat at the leading edge and fold the front half over the rear half of the luggage compartment mat. M Applies to S60 Slide the entire luggage compartment mat slightly forward, turn it slightly to be able to remove it through the luggage compartment opening. M Applies to S60 Remove the luggage compartment mat. Side 16 / 21

17 29 Applies to S60 Press in the centre on the clips at the lower edge of the foldable side panel's right side until a 'snap' is heard. Remove the clips. M Applies to S60, S80 Turn the handle (1) on the right side 90º. Fold in the side panel and lift it out. M Applies to S60, S80 Remove: the clips (1) in the right front side panel in the luggage compartment. the clip (2) at the top at the leading edge on the side panel roof foldable headrest. the panel. M Side 17 / 21

18 32 Route the cable from the rubber leadthrough out to the body's right side in front of right rear door and clamp it ti existing cable harnesses with a new cable tie. Continue to route the cable along the car's right side inside the mats and in the lower edge of the door sills to the leading edge of the right rear wheel housing. Route the cable under the insulation on the left side of the backrest's lower edge and along the right side of the cable channel and the floor support onto the trailing edge of the right rear wheel housing. Clamp the cable to the cable channel with new cable ties (2). Press down the cable between the right side of the floor support and the insulation mat over the wheel housing. Make sure that the cable does not rest on sharp edges or similar. M Loosen the screw (1) for the lock plate for the AEM module. Pull loose the lock plate and carefully pull up the control module from its bracket. M Disconnect the big connector from the control module by pressing in the catch (A) and pulling the lock handle (B) in the direction of the arrow until a 'snap' is heard. Unplug the connector from the control module. M Side 18 / 21

19 35 Remove the catch cover that holds the contact in place in the connector by pulling it loose in the direction of the arrow. Remove the contact by inserting a pointed object in the hole on the other end and pressing it out. M Connect the routed cable to the AEM module's connector in position 5. Note! The number markings are on the top and underside of the connector, they are very small so be careful when installing the cable. M Side 19 / 21

20 37 Reinstall the contact in the connector and lock it into place with the catch cover. Press the connector into the control module and lock with the lock handle. Press the control module into its bracket. M Reinstall the lock plate under the screw head and tighten the screw. Torque-tighten with 10 Nm (8 lbf.ft). M Turn the ignition key to position II. Connect the battery's minus cable. Program the software according to service information in VIDA. Program any radio code. Reinstall the insulation mat in the luggage compartment. Reinstall panels in the luggage compartment. Reinstall the floor hatches. A Reinstall the sill panel in the right rear door. Side 20 / 21

21 Reinstall the side cushion. Fold back the seat cushion. Fold back the backrest. Fold back the mat right front. Reinstall the sill panel in the right front door. Reinstall the right sound wall. Reinstall the tunnel console's right side panel. Reinstall the engine protection plate. Reinstall the middle air baffle. Reinstall the air baffles for the front brakes if these were removed. Side 21 / 21