Digital Jukebox, S60, without RTI: Notes

NOTE:

In certain cases, the car can already be pre-wired with DIN-cable. If this is the case, make sure that there is a brown ground cable. If there is no brown ground cable, then kit cable A must be used.

Fig 1: Identifying Ignition Switch OFF & Disconnected Negative Battery Lead

GLL102428

Courtesy of VOLVO CARS OF NORTH AMERICA.

Move the left-hand front seat to its rear position.
Turn the ignition switch to position 0.
On cars with manual gearbox. Remove the ignition key.
Disconnect the battery negative lead.
NOTE:
Wait at least five minutes before disconnecting the connectors or removing other electrical equipment.

Fig 2: Prying Off Panel In Front Of Gear Selector Lever

GLL107058

Courtesy of VOLVO CARS OF NORTH AMERICA.

Applies to cars up to and including model year -2004 (CH -424999)

Remove the panel in front of the gear selector lever. Pry off the panel using a plastic weatherstrip tool.
Move the gear selector lever to the rear position.

Fig 3: Detaching Gear Lever Cover Panel With Boot

GLL146549

Courtesy of VOLVO CARS OF NORTH AMERICA.

Applies to cars from model year 2005- (CH 425000-)

Carefully prize away the gear selector lever cover panel together with the boot until the two clips release. Use a plastic weatherstrip tool. Pull the panel up until the four clips at the sides release.

Fig 4: Identifying Bolts In Dashboard Environment Panel

GLL107095

Courtesy of VOLVO CARS OF NORTH AMERICA.

Applies to cars up to and including model year -2004 (CH -424999)

Remove the two screws from the dashboard environment panel.

Fig 5: Engaging Handbrake And Moving Gear Selector Lever Towards Rear To Remove Screws

GLL146551

Courtesy of VOLVO CARS OF NORTH AMERICA.

Applies to cars from model year 2005- (CH 425000-)

Engage the handbrake and move the gear selector lever towards the rear.
Rotate the panel to the left for better access.
Remove the two screws holding the bracket with the radio and dashboard environment panel in the center console.

Fig 6: Angling Dashboard Environment Panel Out

GLL107097

Courtesy of VOLVO CARS OF NORTH AMERICA.

Applies to cars up to and including model year -2004 (CH -424999)

Angle the dashboard environment panel outwards so that it is possible to insert a couple of fingers between the center console and the short side of the dashboard environment panel.
Pull the dashboard environment panel downward maintaining the same angle and remove the dashboard environment panel. The panel is well secured, so some force is required to detach the panel. Unplug the connectors on the reverse side, and place the dashboard environment panel to one side.
NOTE:
If any of the outer hooks break off, these must be repaired.

Fig 7: Removing Bracket With Dashboard Environment Panel And Radio From Center Console

GLL146553

Courtesy of VOLVO CARS OF NORTH AMERICA.

Applies to cars from model year 2005- (CH 425000-)

Remove the bracket with dashboard environment panel and the radio from the center console: Pull the lower edge out and downwards until it releases from the mounting at the upper edge. Then fold backwards.
NOTE:
Do not damage the removed components or the surrounding panels. If necessary, the panel around the gear selector lever can be removed for additional space. The panel is secured with four catches on the underside along the boot.
Unplug the connectors from the radio and dashboard environment panel, and from the telephone keypad if applicable. Place the unit to one side.

Fig 8: Identifying Screws From Bracket For Radio

GLL106297

Courtesy of VOLVO CARS OF NORTH AMERICA.

Applies to cars up to and including model year -2004 (CH -424999)

Remove the screws from the bracket for the radio.
Pull out the bracket with the radio. Pull the lower corner while pressing downwards.
Unplug the connectors from the radio and the telephone keypad if applicable, and remove the bracket with the radio.

Fig 9: Removing Side Panel And Sill Trim Panel

GLL149320

Courtesy of VOLVO CARS OF NORTH AMERICA.

Applies to all models

Remove the side panel (1) on the center console. First twist the clip at the rear edge of the panel a 1/4 turn counter-clockwise. Pull the rear edge of the panel outwards and backwards.
Remove the sill trim panel (2).

Fig 10: Identifying Seat Cushion

GLL105084

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the seat cushion (1). First lift the front edge, pull it forwards and lift it out.

Fig 11: Removing Sill Molding For Left-Hand Rear Door

GLL107053

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the sill molding for the left-hand rear door.

Fig 12: Folding Left Hand Rear Backrest Forward And Removing Seat Belt From Guide

GLL107191

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fold the left-hand rear backrest forward.
Take the seat belt out from the guide (1).
Repeat the operation on the other side.

Fig 13: Identifying Clip At Side Of Left-Hand Side Cushion

GLL107193

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the clip (1) at the side of the left-hand side bolster.
Pull the top edge of the left-hand front cargo compartment panel out to access the upper catch for the side bolster.
Repeat the operation on the other side.

Fig 14: Pressing In Catches At Top Edge Of Reverse Of Side Cushion

GLL107194

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the left-hand side bolster. First press in the catch (1) at the top of the reverse of the side bolster, and pull it out slightly.
Grasp the bolster using both hands. Twist counter-clockwise until the catch on the inside releases.
Remove the side bolster. First pull out the top of the side bolster. Then pull upwards.
Repeat the operation on the other side.

Fig 15: Removing Cover And Screw In Left-Hand C-Post Panel

GLL107217

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the cover and screw in the left-hand C-pillar panel.
Repeat the operation on the other side.

Fig 16: Pressing Panel Inwards Until Three Clips Release

GLL107218

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the rubber strip at the rear edge on the left-hand rear door frame
Grasp the top edge of the C-post panel. Pull (A) the panel inwards until the three clips (1) release
Then pull (B) the panel straight up. Place the panel to one side
Repeat the operation on the other side.

Fig 17: Identifying Parcel Shelf Clips And Guide Pins

GLL107219

Courtesy of VOLVO CARS OF NORTH AMERICA.

Carefully lift the front edge of the parcel shelf until the clips (1) release.
Raise the panel more until the guide pins (2) disengage from their holes.
Pull out the parcel shelf and lay it on the folded backrests.

Fig 18: Identifying Side Panel Clips And Plastic Nut

GLL107704

Courtesy of VOLVO CARS OF NORTH AMERICA.

Lift out the cargo compartment carpet.
Press in the center of the clips on the lower edge of the folding side panel on the left-hand side until a click is heard.
Remove the two clips.
Remove the plastic nut at the front/lower edge of the side panel.

Fig 19: Folding Side Panel Inwards And Remove It

GLL107195

Courtesy of VOLVO CARS OF NORTH AMERICA.

Turn the knob (1) on the left-hand side through 90°.
Fold the side panel inwards and remove it.

Fig 20: Locating Clips

GLL150701

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the clips (1) and plastic nut from the left front side panel in the cargo compartment.
Remove the front side panel.

Fig 21: Route DIN Cable Up Between Front Air Duct And Strut For Center Console

GLL150702

Courtesy of VOLVO CARS OF NORTH AMERICA.

Take the DIN cable from the kit, lift up the floor carpet and route it underneath, up between the front air duct (1) and the strut (2) for the center console.
NOTE:
Make sure that it is the connector with a guide pin which points upward (see illustration), which is routed to the radio socket.
Route the cable through the compartment for the radio.
Clamp the cable in the strut (3), using the clamp from the kit.
Route the cable on above and alongside the front air duct to the member (4) for the seat mounting.
Clamp the cable at the existing cable harness (5).

Fig 22: Route Cable Under Carpet, Along Front Cable Duct, And Along Right-Hand Side Of Rear Cable Duct

GLL150703

Courtesy of VOLVO CARS OF NORTH AMERICA.

Route the cable (1) under the carpet, along the left-hand side of the car to the rear door.
Route the cable further under and along the front cable duct (2). Continue along the right-hand side of the rear cable duct (3).

Fig 23: DIN Cable Routed Along Two Cable Ducts/Cable Harness

GLL150704

Courtesy of VOLVO CARS OF NORTH AMERICA.

Route the DIN cable (1) along the two cable ducts/cable harness (2) under the insulation panel and out through the hole in the body to the cargo compartment.
Route the DIN cable under the four connectors in the front cable duct.

Fig 24: Power Supply, Ground, Rear Cable Duct And Cables

GLL150705

Courtesy of VOLVO CARS OF NORTH AMERICA.

Applies to cars up to and including model year -2004 (CH -424999)

Take the cable harness for power supply (1) from the kit. Connect the ground lead to the rear ground terminal (2) under the seat cushion. Tighten to 10 Nm (7 lbf.ft.) .
Route the ground lead under the four connectors in the front cable duct.
Route the power supply cables (1) along the rear cable duct (3) under the insulation panel and out through the hole in the body to the cargo compartment. Position the cable end with the two red/white (R/W) single cables and the two green connectors at the rear fuse holder. Route the long cable with the green connector (4) to the pre-routed DIN cable's connector.

Fig 25: Power Supply, Ground, Rear Cable Duct And Cables

GLL150706

Courtesy of VOLVO CARS OF NORTH AMERICA.

Applies to cars from model year 2005- (CH 425000-)

Take the cable (1) for power supply from the kit. Connect the ground lead to the existing ground terminal behind the battery. Tighten the screw. Tighten to 10 Nm (7 lbf.ft.) . Position the cable end with the two red/white (R/W) single cables and the two green connectors (2) by the rear fuse holder.
Route the cable harness on the left-hand side of the cable duct. Route the long cable with the green connector (3) to the pre-routed DIN cable's connector.

Fig 26: Identifying Drilling Locations

GLL150707

Courtesy of VOLVO CARS OF NORTH AMERICA.

HINT: Two people should assist with drilling the holes and installing the Jukebox and console.
Take the Jukebox console from the kit and position it against the panel under the parcel shelf on the left-hand side as shown in the illustration, hold it still and mark out the rear hole in the right-hand side of the console.

NOTE:
Do not damage the cables while drilling.

Use protective safety goggles if lying in the cargo compartment to drill.
Drill the hole using a Ø 6 mm (15/64") diameter drill bit, and deburr it.
Take four M5 screws, washers and nuts from the kit. Install the console with one screw in the drilled hole. Tighten the screw by hand.
Align the console so that it is straight.
Mark out the three remaining holes. Remove the console.
Drill the three remaining holes, deburr them and apply anti-corrosion protection to the edges of the holes.

Fig 27: Pressing Spacer Washers Into Holes

GLL151369

Courtesy of VOLVO CARS OF NORTH AMERICA.

Take the console and spacer washers from the kit and press the washers into the holes in the bottom of the console.

Fig 28: Identifying Jukebox

GLL151370

Courtesy of VOLVO CARS OF NORTH AMERICA.

Take the Jukebox with the blind rivets and plastic washers from the kit, position it over the spacer washers installed in the console.

Fig 29: Positioning Plastic Washers Over Spacer Washers

GLL151371

Courtesy of VOLVO CARS OF NORTH AMERICA.

Turn the whole unit upside-down and place a soft separator panel on the top of the Jukebox, so that it is pressed against the bottom of the console.
Take the four plastic washers and position them over the spacer washers previously installed.

Fig 30: Riveting Jukebox Into Console Using Blind Rivets

GLL151372

Courtesy of VOLVO CARS OF NORTH AMERICA.

Take the four blind rivets and rivet the Jukebox into the console.

Fig 31: Locating Jukebox Connector Screws

GLL151373

Courtesy of VOLVO CARS OF NORTH AMERICA.

Take the adapter cable from the kit and connect in the corresponding socket in the rear edge of the Jukebox.
Tighten the connector screws.
Position the cables on the inside of the rear of the console.
Take a tie strap from the kit and clamp in the cable at one corner of the console as shown in the illustration.

Fig 32: Installing Console And Jukebox

GLL150708

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install the console and the Jukebox with four screws, washers and nuts to the underside of the parcel shelf and tighten.

Fig 33: Identifying Cables And Tie Straps

GLL159529

Courtesy of VOLVO CARS OF NORTH AMERICA.

Connect the DIN cable and the long cable with the green connector in the pre-routed cable harness to the Jukebox adapter cable.
Connect the brown ground cable (1) with matching cable on the jukebox.
Clamp the cables in the body and at the existing cable harnesses with tie straps from the kit. Make sure that the cables do not chafe against sharp edges in the body.