Operation CHARM: Car repair manuals for everyone.
Hosted by mcallihan.com
Home >> Volvo >> 2005 >> XC90 AWD V8-4.4L VIN 85 B8444S >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Cylinder Block Assembly >> Engine Block Heater >> Service and Repair >> Relay >> Part 1

Part 1













Relay, B6294, B8444
































Relay

Note!
- Steps 1 - 46 apply to the XC90
- Steps 47 - 73 apply to the S80

Steps - apply to the XC90




- Turn the ignition switch to position 0.
- Remove the right-hand side panel of the centre console by pulling it away starting at the front edge and then backwards until all clips have released.
- Remove the sound barrier on the right-hand side by first removing the two screws and then prizing it away at the top edge.




- Remove the cover panel on the right-hand rear mounting of the right-hand front seat. Prize it up slightly at the rear edge and then pull it back/upwards.




- Carefully prize away the cover panel over the joint between the door sills on the right-hand side, at the lower edge, using a weatherstrip tool. Remove the cover panel.




- Detach the right-hand front door's sill trim panel. Pull it away starting at the front edge until the clip there has released. Continue backwards until the remaining clips have released.
- Unhook it from the B-pillar panel and place it to one side.




- Remove the screws to the passenger compartment connector socket and detach it from the bracket behind the carpet.
- Remove the locking sleeve and detach the cable from the passenger compartment connector socket.




- Push the carpet to one side by the right-hand front seat.
- Press out the rubber grommet (1) under the insulation mat.




- Remove the panel in the right-hand front seat mounting, on the right-hand seat in the second row of seats. Push up the catch (1) on the top side and pull the panel forward.




- Fold the backrest forward on the right-hand seat in the second row of seats as far as possible. Push the seat forward as far as possible. (On cars with two rows of seats the second row is fixed.)
- Remove the cover panel (1) for the right-hand rear seat mounting by prizing it away at the rear edge.




- Disconnect the top edge of the sill trim panel. Disconnect the seat belt from the end mounting by carefully pressing the locking tab with a weatherstrip tool, as illustrated, so that the seat belt releases from the end mounting.




- Remove the sill trim panel by pulling it away completely at the rear edge until the clips there have released. Continue forwards until the remaining clips have released.

Applies to cars with two rows of seats
- On cars with two rows of seats, the seat cannot be pushed forward. To remove the sill trim panel, start by folding the backrest forward as the sill trim panel is pulled away at the rear edge. Following which, move the backrest back to raise the seat cushion, and so increase space for removing the sill trim panel. It is secured firmly, so ensure that the sill trim panel and adjoining components are not damaged during removal.

Illustration A





Applies to cars with two rows of seats
- Remove the two centre floor hatches by lifting them slightly and then pulling them away from their mountings at the front edge. If the rear centre floor hatch is equipped with grocery bag holder on the underside then the floor hatch is secured with a belt on each short side of the storage box. These must be detached.
- Remove the storage box.

Illustration B





Applies to cars with three rows of seats and integrated carrier bag holder on the underside of the centre floor hatch
- Fold up the centre rear floor hatch (1).
- Detach the two straps on the underlying panel. Lift up the rear edge of the panel, fold the floor hatch back and lift out the floor hatch with the panel.

Applies to cars with three rows of seats without an integrated carrier bag holder
- Lift up the centre rear floor hatch at the rear edge and lift it out.

Applies to all models
- Remove the right-hand side floor hatch (2).





Applies to cars with two rows of seats
- Remove the front storage box.




- Remove the folding side panel from the right-hand side of the cargo compartment.




- Detach the left-hand headlamp by pulling up the two locking pins and then carefully pulling the headlamp away forwards.




- Carefully prize up the catch on the connector for the headlamp using a screwdriver.
- Pull the catch up completely, detach the connector and place the headlamp to one side.





Applies to cars with V8 engine
- Remove the branch connector with the cables from the underside of the plate beneath the headlamp. Remove the screw, nut and washer (1) and tie strap (2), and pull the branch connector forward.





Applies to cars with 6-cylinder engine
- Remove the branch connector with the cables from the underside of the plate beneath the headlamp by removing the screw and the nut (1).
- Cut away the tie strap (2).





Applies to all models
- Remove the locking sleeves over the joints on the branch connector and pull the cables away from it.
- Place the branch connector to one side, it shall not be re-used.





Applies to all models
- Take the relay with cable from the kit.
- Grease in the O-ring on the connector for the front socket and both connectors on the relay using low temperature grease (part no. 1161417-9).

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





Applies to all models
- Connect the cable (1) from the front socket to the relay.
- Connect the cables to the engine block heater and passenger compartment connector socket to either of the sockets (2) or (3) on the relay and press them in firmly.





Applies to cars with V8 engine
- Take three locking sleeves from the kit and press them in over the cable joints.





Applies to cars with 6-cylinder engine
- Take three locking sleeves from the kit and press them in over the cable joints.
- Take a tie strap (1) from the kit and clamp the electrical cable securely with the ground cable to one of the cables for the engine block heater/passenger compartment connector socket.





Applies to cars with V8 engine
- Take the relay with cables and fit it on the underside of the plate beneath the headlamp. Fit the relay with the side against the plate that allows the connector to be accessible.
- Take a screw, washer and nut (1) from the kit. Tighten the relay to the plate.
- Guide the relay's ground cable (2) down on the left-hand side of the side member.
- The long thin cable (3) from the relay is routed the same way as the cables for the heater and the passenger compartment connector socket, to enable later connection to the Accessory Electronic Module (AEM) in the cargo compartment.
- Clamp the ground cable with the cable to the front socket using a tie strap from the kit.





Applies to cars with 6-cylinder engine
- Take the relay with cables and place it on the underside of the plate (1). Fit the relay with the side against the plate that allows the connector to be accessible.
- Take a screw, washer and nut (2) from the kit. Tighten the relay to the plate.
- Clamp the cable for the front socket at point (3) in the plastic eye for the bumper cover's mounting.
- Guide the thin cable with the ground cable from the relay down to the same location as the cables for the engine block heater/passenger compartment connector socket.
- Clamp all cables together at point (4) with a tie strap from the kit.

Steps 25 - 34 apply to the XC90 with V8 engine




- Route the cable to the Accessory Electronic Module (AEM) the same way as the cable for the passenger compartment connector socket under the plate, beneath the left-hand headlamp. Route it backwards along the left-hand side of the air cleaner and between the air cleaner and fuse holder. Continue to route it backwards, under the ABS system and up between the cable duct and brake fluid reservoir.
- Check that the cable does not chafe against sharp edges or moving parts in the engine compartment.
- Route it along the cable for the passenger compartment connector socket over to the right-hand side of the car and down through the engine compartment.
- Clamp the cable securely the whole way with the cable for the passenger compartment connector socket using tie straps from the kit.




- Remove the right-hand front wheel for easier access for routing the cable to the Accessory Electronic Module (AEM).




- Remove the two plastic nuts which hold the small protective panel in the right-hand wheel housing, and remove the panel.




- Remove the six screws and the engine splash guard.




- Detach the existing ground cable for the front socket on the underside of the left-hand frame member.
- Route the ground cable on from the relay. Connect both ground cables to the existing ground terminal and tighten the ground screw firmly.




- Detach the cable for the passenger compartment connector socket from the clip in the edge of the plate, at the bending rubber hose for the water drainage.
- Route the rubber grommet with cable out to the passenger compartment connector socket from the passenger compartment.
- Remove the rubber grommet from the cable and place it to one side. There is a new rubber grommet on the routed cable.




- Cut away the very top of the rubber grommet.




- Grease in the rubber grommet using low temperature grease part no. 1161417-9 in order to make it easier to install the rubber grommet in the hole in the cowl.
- Guide the cable into the rubber grommet.




- Guide both cables into the hole in the cowl and press the rubber grommet into place in the hole, either by pulling it into place from inside the passenger compartment, or carefully pressing it into place with a long large screw driver/wide end of a short pry bar.

Note! These must not be sharp or they can damage the cables/rubber grommet

- Adapt the length of the cable from the rubber grommet, at the installed clip and out in the engine compartment.




- Press the cables for the passenger compartment connector socket/Accessory Electronic Module (AEM) into the installed clip. Make sure that the cable with the radiation shield is firmly pressed into the clip and does not slide out.

Caution! Check that the cables are routed so that they do not come into contact with the alternator belt, or chafe against sharp edges in the engine compartment.

- Clamp the cable for the Accessory Electronic Module (AEM) with the thick cable using tie straps from the kit.
- Reinstall the small protective panel in the wheel housing.
- Reinstall the engine splash guard and torque tighten the screws to 25 Nm (18.5 lbf.ft.).
- Remount the wheel and tighten the bolts to 140 Nm (103 lbf.ft.).
- Connect and reinstall the left-hand headlamp.

Steps 35 - 38 apply to the XC90 with 6-cylinders




- Remove the screws (2) and the engine splash guard (1).




- Route the electrical cables down from the relay.
- Take four tie straps from the kit and clamp the thin electrical cable (not the ground cable) to the cable for the passenger compartment connector socket.




- Detach the existing ground cable for the front socket on the underside of the left-hand frame member.
- Route the ground cable on to the relay. Connect both ground cables to the existing ground terminal.


pro multis · About Operation CHARM