Passenger Compartment Connector Socket

Passenger compartment connector socket

INTRODUCTION
- Read through all of the instructions before starting installation.
- Notifications and warning texts are for your safety and to minimize 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.

Passenger compartment connector socket

Note!
- Steps 1-24 are for cars with 5-cyl. gasoline engine (B5244, B5254T)
- Steps 25-51 are for cars with diesel engine (D4204T)

For cars with 5-cylinder gasoline engine

- Open the glove compartment lid.
- Remove the panel on the right-hand end of the dashboard by carefully prying it loose all around with a weatherstrip tool, until the three clips on the inside release.

Note! Do not damage the dashboard.

- Remove the sill trim panel of the right front door by pulling it starting at the front edge until the clip releases. Then continue rearward until the remaining clips on the underside have released.
- Unhook the it from the B-post panel.

- Move the carpeting aside to access the grommet in the firewall and install the passenger compartment connector.
- Unscrew the clip holding the insulating mat to the body. Put it aside. It will not be used again.

- Remove the right-hand front wheel.
- Remove the seven screws holding the engine splash guard and remove the guard.

- Cut the cable tie from around the brace and over the locking sleeve on the brace on the right control arm mounting.
- Remove the locking sleeve over the cable splice and separate the cables.

Installing the junction connector

- Grease the O-ring of the front intake cable, the passenger compartment connector cable and the junction connector with low-temperature grease (part no. 1161417-9).

Note! Do not get any grease on the surfaces of the connector.

- Take the bracket and the rubber guard from the kit for the passenger compartment connector. Press the rubber guard onto the bracket.

- Tighten the junction connector at the bracket in the position illustrated. Use the screw, toothed washer and nut from the kit. The bracket must be parallel to the length of the junction connector.
- Position (1) cable for the engine block heater
- Position (2) cable for the passenger compartment connector
- Position (3) cable from the front engine block heater socket.

- Detach the cable from the front intake and engine heater from its clamps/clips to facilitate installation of the passenger compartment junction connector.
- Connect the front intake cable (1) to the junction connector. Press the cable splice together securely.

- Press the existing locking sleeve over the splice of the front intake cable.

- Connect the engine heater cable (1).
- Connect the cable (2) from the kit to the passenger compartment connector.
- Press the cables securely into the junction connector

- Press in the two locking sleeves from the kit over the cable splices.

- Fit the rubber guard from the kit over the hose clamp.

Illustration A

Illustration B

Illustration C

- Fasten the junction connector with the connected cables to the brace (1) (Illustration A) using the hose clamp (2) (Illustrations A and B) and the bracket on the junction connector. Make sure that the junction connector ends up at the center of the brace. Adjust the position of the junction connector until the measurement is 135 mm (5 5/16") (Illustration C).
- Tighten the hose clamp securely.
- Reinstall the cables of the engine heater and front intake in their clamps.

Cable routing

- Make a hole in the insulating mat to access the rubber grommet in the firewall.

- Use a knife to to cut away the top of the large "rubber tip" in the firewall on the lower right side of the engine compartment.

- Take the thermal insulator and cable tie from the kit. Fit the thermal insulator on the passenger compartment connector cable. If the insulator is too long, cut it to a suitable length (it should cover the cable between the junction connector/timer relay and firewall grommet). Pull on the thermal insulator as far towards the junction connector as it will go.
- Tighten the tie strap.

- Grease the rubber grommet with low-temperature grease (part no. 1161417-9) so that the connector slides through more easily.
- Insert the passenger compartment connector cable through the rubber grommet and into the passenger compartment. Guide all excess cable into the passenger compartment.
- Reinstall the engine splash guard.
- Remount the wheel and tighten the lug bolts to 90 Nm (66 lbf.ft.).

- Route the cable from the rubber grommet to the firewall. Route it behind the cables to the electrical distribution box.

Installing the passenger compartment connector socket

- Move aside the insulating mat to drill holes for the passenger compartment connector bracket.
- Clean away sealant where one corner of the bracket will sit.
- Fit the bracket from the kit on the pin of the insulating mat's clip. Use the plastic nut from the kit.
- Align the bracket so that its edge (1) is parallel to the edge (2) in the front edge of the door opening.
- Drill the hole (3) in the body through the bracket using a - 3.5 mm (9/64") bit.
- Deburr the hole edges and apply anti-corrosion agent to them.
- Secure the bracket using a plastic nut bolt from the kit.

- Reposition the insulating mat over the bracket. Use a carpet knife to make a cut in the insulating mat so that the bracket is visible.

- Reposition the carpeting over the bracket. Make holes in the carpeting for the screws to fasten the passenger compartment connector.

- Connect the cable to the passenger compartment connector and secure it.
- Press a locking sleeve from the kit over the cable splice.

- Secure the passenger compartment connector to the bracket using screws from the kit.
- Reinstall the sill trim panel in the right-hand front door.
- Reinstall the right end panel of the dashboard.

Applies to cars with diesel engine

- Remove the sill trim panel of the right front door by pulling it starting at the front edge until the clip releases. Continue rearward until the remaining clips on the underside have released.
- Unhook the it from the B-post panel.

- Remove the left front wheel.
- Remove the seven screws holding the engine splash guard and remove the guard.

- Cut the cable tie from around the brace and over the locking sleeve on the brace on the left control arm mounting.
- Remove the locking sleeve over the cable splice and separate the cables.

Installing the junction connector

- Take the bracket and the rubber guard from the kit for the passenger compartment connector. Press the rubber guard onto the bracket.

- Press the existing locking sleeve over the splice of the front intake cable.

- Connect the engine heater cable (1).
- Connect the cable (2) from the kit to the passenger compartment connector.
- Press the cables securely into the junction connector

- Press in the two locking sleeves from the kit over the cable splices.

- Fit the rubber guard from the kit over the hose clamp.

Illustration A

- Fit the junction connector with the connected cables onto the brace (1) using the hose clamp (2) and holder on the junction connector. Make sure that the junction connector ends up in the middle of the brace.

Illustration B

- Adjust the position of the junction connector so that the measurement is 135 mm (5 5/16").
- Tighten the hose clamp securely.
- Reinstall the cables of the engine heater and front intake in their clamps.

Cable routing

- Route the cable (1) to the top of the engine compartment.
- Clamp the electrical cable with a double clamp at the lower of the two horizontal brake pipes at the top edge of the firewall.

- Install three clips from the kit on the front edge of the panel above the windscreen wiper motor.
- Guide the cable up to the top of the engine compartment to the position illustrated.

Illustration A

- Press the passenger compartment connector cable into the clips. Guide down the cable at point (1) and route down through the engine compartment (behind the AC pipes) down to the stay in the right link arm mounting.

Illustration B

- Clamp the cable from the top of the engine compartment and down using a tie strap (Illustration B) and double clamp (Illustration C) at existing cables and pipes.

Note! The cable must not be clamped directly to AC, fuel or brake pipes.

Illustration C

- Make a hole in the insulating mat to access the rubber grommet in the firewall.

- Use a knife to to cut away the top of the large "rubber tip" in the firewall on the lower right side of the engine compartment.

- Take the thermal insulator and cable tie from the kit. Fit the thermal insulator on the passenger compartment cable connector. If the insulator is too long, cut it to a suitable length.

- Grease the rubber grommet with low-temperature grease (part no. 1161417-9) so that the connector slides through more easily.
- Insert the passenger compartment connector cable through the rubber grommet and into the passenger compartment. Guide all excess cable into the passenger compartment.
- Slide the thermal insulator toward the rubber grommet in the firewall and clamp it with the tie strap from the kit.
- Reinstall the engine splash guard.
- Remount the wheel and tighten the lug bolts to 90 Nm (66 lbf.ft.).

- Route the cable from the rubber grommet to the firewall. Route it behind the cables to the electrical distribution box.

Installing the passenger compartment connector socket

- Reposition the insulating mat over the bracket. Use a carpet knife to make a cut in the insulating mat so that the bracket is visible.

- Reposition the carpeting over the bracket. Make holes in the carpeting for the screws to fasten the passenger compartment connector.

- Connect the cable to the passenger compartment connector and secure it.
- Press a locking sleeve from the kit over the cable splice.

- Secure the passenger compartment connector to the bracket using screws from the kit.
- Reinstall the sill trim panel in the right-hand front door.
- Reinstall the right end panel of the dashboard.