Reverse warning system (7)

Illustration A applies to the S40

Illustration B applies to the V40

• Make a note of the anti-theft protection radio code if applicable
• Switch off the ignition
• Disconnect the battery negative lead
• Remove the 2 screws, the cargo compartment carpet and the rear wall panel
• Remove the clip (A) and turn the rear panels inwards on the left and right-hand sides. (For V40 with auxiliary loud speakers: See points 2, 3 and 4).

Applies to the S40

• Remove the entire left-hand panel in the cargo compartment.

Applies to V40 models with extra loud speakers:

• Angle the rear seat forwards. Fold the right-hand backrest down
• Remove the fixed section (A) on the right-hand backrest.

Applies to V40 models with extra loud speakers:

• Remove the parcel shelf
• Press together the clips. Pull off the cargo net from the reverse of the panel in the cargo compartment
• Remove the clip (A). Remove the screw (B)
• Where applicable: Remove the mountings for the protective net
• Remove the cargo compartment panel from underneath. Use a twisting movement.

Applies to V40 models with extra loud speakers:

• Disconnect the grey (GR) connector (one or more)
• Remove the 4 screws
• Remove the extra loudspeaker.

• Remove the 3 mounting screws / clips for the splashguards
• Remove the screw (A)
• Press in the catch. Disconnect the connector for the side marker lamp in the rear bumper
• The procedure is the same for both the left and right hand sides.

• Remove the nuts (A and B). Remove the screw (C)
• Carry out procedures A, B and C on both the right and left-hand sides
• Up to chassis number 600000: Remove the clip (D) from the underneath of the bumper
• Apply tape under the tail lamps to protect against damage to the paint work when removing the rear bumper
• Remove the rear bumper.

Applies only to V40 models

• Remove the 8 clips and the plastic supports on the right and left-hand sides.

Applies to cars up to chassis number 600 000:

• Remove the clips (A) from on top
• Remove the clips (B) from underneath
• Press in the catches. Remove the bracket for the bumper. (Some force is required to remove the bracket).

• Press in the catches. Remove the bracket (A)
• Start at one end. (Some force is required to remove the bracket.)
• Remove the two clips (B)
• Press in the catches. Remove the reinforcement (C). Start at one end.

Illustration A applies to cars with chassis numbers up to 600 000

Illustration B applies to cars with chassis numbers from 600 000

• Remove the shock absorbent rubber liner from the bracket
• Mark for holes in the bracket and liner as illustrated. Saw out holes using a pneumatic saw
• Reinstall the rubber liner in the bracket (use tape on the outside).

Illustration A applies to cars with chassis numbers up to 600 000

Illustration B applies to cars with chassis numbers from 600 000

• Find the centre of the bumper
• Apply masking tape to the surface surrounding the hole marks on the outside of the bumper
• Mark for four holes as illustrated
• Drill four 8.5 mm (21/64") diameter holes.

Illustration A applies to cars with chassis numbers up to 600 000

Illustration B applies to cars with chassis numbers from 600 000

• Apply the special tool (Volvo P/N 9814069). Drill four 31 mm (1/4”) diameter holes. Drill from the outside. Do not damage the paintwork on the bumper.

NOTE! The temperature of the bumper must be at least 15° C (60° F)

• Clean the inside of the bumper at the sensor holder. First use sandpaper and then cleaner H (Volvo P/N 1161436)
• Clean the inside using cleaning agent (P/N 9192678)
• Treat the inside of the bumper using Activator (P/N 8637076) at the sensor holder. (Leave at least 10 minutes to dry).

NOTE! The temperature of the sensors must be at least 15°C (60° F)

• Clean the holders for the sensors. Use cleaner H (Volvo P/N 1161436)
• (Use cleaning agent (P/N 9192678). Treat the mounting surfaces of the sensors using Activator (P/N 8637076). (Leave at least 10 minutes to dry.)
• Install the sensors in their holders
• Remove the masking tape and apply protective film to the sensor holders.

• Remove the masking tape. Install the sensor holders on the bumper. The thin section must be pointing upwards
• Ensure that the sensor holders are mounted straight.

Примечание: The function may be impaired if the sensors are not positioned correctly.

Applies to cars up to chassis number 600 000

• Примечание: > Do not damage the paintwork on the bumper.

Press the bracket for the bumper into place. Ensure that all catches engage
- Install the clips (A) and (B).

Applies to cars from chassis number 600 000

• Cut out three lines in the plate bracket. Bend in the bracket at these three points. (Use a pneumatic saw)
• Spray or paint rust solvent on the bracket.

• Примечание: > Do not damage the paintwork on the bumper.

Check that the bumper (D) is still in the reinforcement (C)
- Install the reinforcement (C) in the bumper cover. (Note the positions of the three guide lugs (G).) Start at the ends and work in towards the centre
- Install the clip (B)
- Install the bracket (A) in the reinforcement for the bumper. Start pressing in the ends and work in towards the centre
- Ensure that all the guide lugs are correctly aligned.

• Connect the sensor connectors
• Secure the cable harnesses using tape or tie straps.

Applies only to V40 models

• Install the plastic supports and the 8 clips on the right and left-hand sides.

• Mark out and drill one 8.5 mm (21/64”) diameter hole
• Apply the special tool (Volvo P/N 9814069). Drill one 31 mm diameter hole
• Spray the inside of the holes using rust solvent.

• Clean the sensors and holders using cleaning agent (P/N 9192678-2)
• Apply a thin layer of primer (P/N 8637076-4) to the sensors and holders.

Примечание: The primer must dry for at least 10 minutes before it can be painted.
- Spray the sensor holders and the sensors. Use the same colour code as the car. Use Volvo recommended paint. Only paint the parts that will be visible after installation.

Примечание: Apply a maximum of two layers of paint. Too many layers of paint may have a negative impact on the function of the sensors. However, the sensors must be painted for optimal functionality.
- Remove the protective film from the bumper when the paint has dried.

• Check that the tape under the tail lamps is intact
• Route the cable harness for the sensors to the rear wing liner. Install the rubber grommet. Ensure that the rubber grommet forms a seal
• Reinstall the bumper.

• Install the screw (C) and nuts (A and B). Hand tighten
• Tighten screw (C). Tighten to 50 Nm (37 lbf. ft). Tighten the nuts (A and B). Tighten to 5 Nm (4 lbf. ft). Tighten on both the left and right hand sides.

Applies to cars up to chassis number 600 000

• Install the clip (D) on the underneath of the bumper.

• Connect the connector for the side marker lamp
• Install the screw (A)
• Reinstall the 3 mounting screws / clips for the splashguards
• The procedure is the same for both the left and right hand sides.

Illustration A applies to the S40

Illustration B applies to the V40

• Connect the 12 and 16-pin connectors to the control module
• Remove the backing and apply the double-sided adhesive tape to the control module
• Remove the backing tape and install the control module as illustrated
• Secure the control module using a little force.

Applies only to S40 models

• Route the 2-pin connector along the existing cable harness to the left rear loudspeaker
• Secure one clip on the buzzer. Secure the clip on the edge of the left-hand loudspeaker panel
• Connect the connector.

Applies only to V40 models

• Remove the loudspeaker grille and the screw (A)
• Remove the lighting for the cargo compartment. Remove the wiring
• Remove the screw (B). Carefully remove the panel
• Route the 2-pin connector along the existing cable harness to the left rear loudspeaker
• Connect the connector to the buzzer. Secure the buzzer to the existing cable harness using a tie-strap.

Shut-off switch for the reverse warning sensor (Used when reversing with a trailer for example.):

Illustration A applies to the S40

• Position the switch (1) beside the buzzer under the parcel shelf. Mark for drilling.

Illustration B applies to the V40

• Position the switch (1) in the protective cover for the left tail lamp. Mark for drilling.

Applies to both

• Drill two 3.5 mm (9/64") diameter holes in the doubled plate
• Install the switch with two screws from the kit
• Route the cable back towards the control module for the reverse warning system.

Reversing lamp:

Illustration A applies to the S40

Illustration B applies to the V40

• Locate the ring cable for the reversing lamps;
• Cut off the cable and install the cable terminal.

• Cut off the cable terminal from the red (R) cable
• Install the cable terminals from the switch. See the illustration.

Ground:

Illustration A applies to the S40

Illustration B applies to the V40

• Connect the cable terminal to the black (SB) cable
• Connect the black (SB) cable to ground on the tail lamp
• Secure all cables using tie straps.

• Remove the tape and clean the rear bumper
• Turn the ignition to position II
• Ensure that no one is inside the car
• Connect the battery negative lead
• Check that the reverse warning sensors are working (activates only when there is an object in the way behind the vehicle when reversing)
• Check the sound signal from the buzzer. The sound signal can be adjusted by turning the outer cover on the buzzer
• Where applicable: re-enter the radio code
• Set the car clock to the correct time
• Reinstall the remaining components.