Electrical - Breakout Box: Other Volvo S60 I

Activation of components

Using this facility, a number of components can be activated to check their function. The following components can be activated

Glow plug

Activating the glow plug.

Note. Important: This function should be activated for no longer than 10-20 seconds.

Heater fan

Activating the heater fan.

A "buzzing" noise is heard from the heater fan when it is activated.

Fuel pump

Activating the fuel pump.

A "buzzing" noise is heard from the fuel pump when it is activated.

Water pump

Activating the water pump.

A "buzzing" noise is heard from the water pump when it is activated.

Heater

Activating the heater.

In case of too low battery voltage or if the heater is in a state that prohibits activation, the heater will abort the activation. In order to enable start of the heater itself, battery voltage shall be normal, coolant temperature must be lower than +96 °C, and the heater's post-run/stop sequence must be completed. There must also be enough fuel in the tank.

Component supply voltage

Activating the relay that provides supply voltage to the water pump, fuel pump and heater fan.

Checking the reserve battery

Note. Applies only to carphones with Volvo On Call.

Scheme 804

Scheme 805

1. Ignition on. Measurement range: 0-100. The value for a battery with full capacity is 100. The reserve battery should be replaced if the value is between 0-40. The carphone module calculates the theoretical capacity of the battery. The battery capacity can be read out either via the combined instrument panel (Driver Information Module) or via VIDA. To activate read out via the combined instrument panel, carry out the following on the carphone module key pad: press the numbers 2, 5, 8 once press the right arrow button twice. To read off using VIDA, click the VCT2000 symbol. Other information: To replace the reserve battery, see «Reserve battery Volvo On Call, replacing»(ref-445824-S36499047472012010600000) .

Connecting the breakout box to the Upper Electronic Module (UEM)

Special tools

9511463

9813190

9511428

9511499

Connecting The Breakout Box

1. Ignition off
2. Remove fuse 11A/4 in the fusebox in the engine compartment
3. Remove the rear view mirror. See «Interior Lighting And Upper Electronic Module (UEM), Replacing»(ref-415246-S28809879202011081500000)
4. Remove the cover from the back of the rear view mirror
5. Disconnect the control module connector.

Connect adapter 9511463 to the upper electronic module (UEM) connector. Connect breakout box 9813190 or breakout box 9511428 and wiring 9511499 to the adapter.

Disconnect the breakout box in reverse order.

For further information about signals and other values, see 2001-2004: Signal specification 2005-2009: Signal specification .

Scheme 806

1. Ignition off
2. Expose the integrated relay / fusebox in the cargo compartment
3. Remove fuses 11D/1 and 11D/2 from the integrated relay / fusebox in the cargo compartment
4. Release the locking hooks on the top of the integrated relay / fusebox in the cargo compartment
5. Fold the integrated relay / fusebox in the cargo compartment downwards / inwards. The integrated relay / fusebox in the cargo compartment can now be removed
6. Slacken off the screw holding the rear electronic module (REM) connector so that it can hang free
7. Disconnect the rear electronic module (REM) connector. The connector may be stiff.

Connect the adapter between the rear electronic module (REM) and its connector. Connect the breakout box to the adapter. Breakout box wiring 9511503 .

Disconnect the breakout box in reverse order.

Note. Before the rear electronic control module can be checked and measurements taken, the removed fuses must first be installed.

Other information

1. For the location of the components, see «Integrated relay/fusebox cargo compartment/Rear electronic module (REM), replacing»(ref-445826-S29484826972012010600000)
2. For further information about signals and other values, see «Signal specification»(ref-445629-S13295021402012010600000) .

Connecting the breakout box to the Transmission Control Module (TCM) (AW)

Special tools

9511428

9511504

Scheme 807

1. Ignition off.
2. Disconnect the automatic transmission control module (TCM)) according to. «Transmission control module (TCM), replacing»(ref-415257-S11654698042011081500000) .
3. Check that the male and female terminals in the control module and control module connector are intact and secure and that the wiring to the female terminals is properly secured to the pins.
4. Pay particular attention to the terminals related to the diagnostic trouble code (DTC)/symptom. See «Signal description. Transmission control module (TCM)»(ref-445824-S13242395092012010600000) .
5. Connect adapter «9511504»(ref-403953-S20513889072011061000000) to the control module connector (wiring side) and connect breakout box «9511428»(ref-403953-S35709646712011061000000) to the adapter.
6. The breakout box is designed to facilitate reading off the control module input and output signals when the control module is connected; and the cable and component resistance when the control module is disconnected. Using a breakout box reduces the risk of accidental short-circuits and damaged connector pins.

Connecting the breakout box to the Transmission Control Module (TCM) (GM)

Special tools

9511504

9511428

9995722

Scheme 808

1. Wait 2 minutes after the ignition has been switched off. The main relay must be voltage free before the control module can be removed from the car. If the engine cooling fan (FC) runs on after the ignition has been switched off, wait until it stops and then a further 2 minutes.
2. Remove control module box cover and put to one side. NOTE: Do not touch the control module terminal pins with your fingers. Static electricity can damage control module components.
3. Insert tool «9995722»(ref-403953-S10522720692011061000000) around the control module.
4. Move the upper section of the tool backwards as far as it will go and pull up the tool.
5. Carefully pull up the control module.

Scheme 809

1. Check that no pins or sockets are damaged on the connector.
2. Gently press adapter «9511504»(ref-403953-S20513889072011061000000) down into the grooves inside the control module box. Press to the limit position.
3. Insert tool «9995722»(ref-403953-S10522720692011061000000) around the adapter.
4. Move the upper section of the tool forwards as far as it will go. Pull the tool up.

Scheme 810

1. Check the control module and control module connectors to make sure that the male and female terminals are undamaged and secure (cannot be pressed in). Check that the cables to the female terminals are secured to the terminal pins.
2. Connect adapter «9511504»(ref-403953-S20513889072011061000000) to the control module connector (wiring side). Connect breakout box «9511428»(ref-403953-S35709646712011061000000) to the adapter.
3. The breakout box is designed to facilitate reading off the control module input and output signals when the control module is connected; and the cable and component resistance when the control module is disconnected. The use of a breakout box reduces the risk of accidental short-circuits and damage to the connector pins.

Scheme 811

1. Wait 2 minutes after the ignition has been switched off. The main relay must be voltage free before the control module can be removed from the car. If the engine cooling fan (FC) runs on after the ignition has been switched off, wait until it stops and then a further 2 minutes.
2. NOTE: Do not touch the control module terminal pins with your fingers. Static electricity can damage control module components.
3. Insert tool «9995722»(ref-403953-S10522720692011061000000) around the adapter.
4. Move the upper section of the tool backwards as far as it will go and pull up the tool.
5. Carefully pull up the adapter.

Scheme 812

1. Check that no pins or sockets are damaged on the connector.
2. Gently press the control module down into the grooves inside the control module box. Press to the limit position.
3. Insert tool «9995722»(ref-403953-S10522720692011061000000) around the control module.
4. Move the upper section of the tool forwards as far as it will go. Pull the tool up.
5. Press the cover over the control modules.
6. Check that the air ducts are correctly positioned.

Connecting the breakout box to the Road Traffic Information (RTI) control module

Special tools

9511463

9511509

9511508

9813194

1. Ignition off
2. Disconnect the required connections from the relevant unit.

Check that the male and female terminals on the unit connectors are undamaged and secure (cannot be pressed in). Check that the cables to the female terminals are secured to the terminal pins.

Other information

1. To access and replace the Road Traffic Information (RTI) control module, see «Road traffic information module (RTI), replacing»(ref-445848-S10274168562012010600000)
2. To access and replace the CD-ROM player, see «CD reader, RTI (road traffic information), replacing»(ref-445846-S33604396582012010600000)
3. To access and replace the GPS receiver, see «Side window, rear, replacing»(ref-445849-S13471611692012010600000) .

Different adapters are required depending on what terminal should be checked on the breakout box.

Terminals A, B, C, J and M should be connected to adapter 9511463 .

Connect terminals D, E, F, L, O and P to adapter 9511509 .

Terminal K should be connected to adapter 9511508 .

Terminal N should be connected to adapter 9813194 .

Road Traffic Information (RTI) Terminals

Terminals #A1-#A22 correspond to terminals #1-#22 on the breakout box.

Terminals #B1-#B14 correspond to terminals #43-#56 on the breakout box.

Terminals #C1-#C16 correspond to terminals #25-#40 on the breakout box.

Terminals #D1-#D6 correspond to terminals #42-#47 on the breakout box.

Terminals #E1-#E8 correspond to terminals #16-#23 on the breakout box.

Terminals #F1-#F13 correspond to terminals #1-#13 on the breakout box.

CD-ROM changer terminals

#J1-#J22 correspond to #1-#22 on the breakout box.

Display terminals

#K1-#K5 correspond to #26-#30 on the breakout box.

Terminals #L1-#L6 correspond to terminals #26-#31 on the breakout box.

TV receiver terminals

#M1-#M16 correspond to #25-#40 on the breakout box.

#N1-#N10 correspond to #47-#56 on the breakout box.

#O1-#O8 correspond to #16-#23 on the breakout box.

#P1-#P13 correspond to #1-#13 on the breakout box.

The breakout box is designed to facilitate reading off the control module input and output signals when the control module is connected; and the cable and component resistance when the control module is disconnected. The use of a breakout box reduces the risk of accidental short-circuited cables and damage to the connector pins.

For further information about signals and other values, see Signal specification, RTI .

Connecting the breakout box. Carphone module (2005-2009)

Special tools

9511463

9511509

9511428

1. Ignition off
2. Expose the carphone module according to «Phone module (PHM), replacing»(ref-445823-S24183743972012010600000) .

Check that the male and female terminals on the unit connectors are undamaged and secure (cannot be pressed in). Check that the cables to the female terminals are secured to the terminal pins.

Connect adapter 9511463 (terminal A, B, C) or 9511509 (terminal E) to the unit connectors (to the wiring). Connect the breakout box 9511428 to the adapter.

Keypad / carphone module terminals

Terminals #A1-#A22 correspond to terminals #1-#22 on the breakout box.

Terminals #B1-#B16 correspond to terminals #25-#40 on the breakout box.

Carphone box terminals

Terminals #C1-#C16 correspond to terminals #25-#40 on the breakout box.

Carphone handset terminals

Terminals #E1-#E8 correspond to terminals #32-#39 on the breakout box.

The breakout box is designed to facilitate reading off the control module input and output signals when the control module is connected, and the cable and component resistance when the control module is disconnected. The use of a breakout box reduces the risk of accidental short-circuited cables and damage to the connector pins.

For further information about signals and other values, see Signal description. Phone module (PHM) .

Connecting the breakout box. Carphone module (2001-2004)

Special tools

9511463

9511509

9813190

1. Ignition off
2. Expose the carphone module according to «Phone module (PHM), replacing»(ref-445823-S14326159212012010600000) .

Check that the male and female terminals on the unit connectors are undamaged and secure (cannot be pressed in). Check that the cables to the female terminals are secured to the terminal pins.

Connect adapter 9511463 (terminal A, C) or 9511509 (terminal D) to the connector for the unit (to the wiring). Connect breakout box 9813190 to the adapter.

Carphone module terminals

Terminals #A1-#A22 correspond to terminals #1-#22 on the breakout box.

Connecting the hands-free in the A-post terminals

Terminals #C1-#C22 correspond to terminals #1-#22 on the breakout box.

Carphone handset terminals

Terminals #D1-#D8 correspond to terminals #32-#39 on the breakout box.

The breakout box is designed to facilitate reading off the control module input and output signals when the control module is connected; and the cable and component resistance when the control module is disconnected. The use of a breakout box reduces the risk of accidental short-circuited cables and damage to the connector pins.

For further information about signals and other values, see Signal description. Phone module (PHM) .

Failed start attempts, value

Reading of the number of failed attempts to start the heater.

If the counter reaches 3 the heater cannot start. A diagnostic trouble code (DTC) is stored in the central electronic module if the counter reaches 1 but the heater can still be started. To set the counter to zero erase the diagnostic trouble codes (DTCs).

Overheating incidents, value

Reading of the number of failed attempts to start the heater. If this parameter counts to 3 the heater cannot be started. To set the counter to zero erase the diagnostic trouble codes (DTCs).

Successful start attempts, value

Reading of the number of successful attempts to start the heater. If the heater can be started 10 times in succession the overheat counter is set to zero. The counter is also set to zero when the diagnostic trouble codes (DTCs) are erased.

Coolant temperature, value

The coolant temperature in the heater.

For cars manufactured up to week 38, 2001 inclusive

The heater cycles between 76 -89 °C (status 5).

For cars manufactured from week 39, 2001 inclusive

The heater cycles between 76 -93 °C (status 5).

Battery voltage, value

The normal value when the alternator is charging is 13.0- 14.0 V. Voltage shall be at least 10.5 V to start the heater.

Measurement range 0 and up.

Heater run time, value

Reading off the number of hours the heater has been running.

Measurement range: 0-65,535 hours.

The heater is designed to run for approximately 4,500 hours.

Additional heater status, value

Heater operating status

0: The heater has not started.

1: The heater starts. Heater self test. The glow plug is activated and then the heater fan.

2: The heater starts and the fuel pump is active. The control module awaits combustion for a certain period of time.

3: The heater runs. Normal heater operation.

4: The heater stops. The flame goes out.

5: The heater waits. Waiting for the engine coolant temperature to be low enough for the heater to start again.

6: The heater has stopped. The heater only has this status if a fault has occurred.

7: The flame is extinguished.

8: Residual heat. If, when the outside temperature is low, the driver is in the car and turns on the heater, the water pump starts in order to heat the passenger compartment.

9: Fuel pump activated. Used in production.

10: Activating the fuel pump. Used to avoid problems with the fuel pump sticking.

Actual combustion fan speed, value

Measurement range 0 - 8000 RPM.

For cars manufactured up to week 38, 2001 inclusive

Normal RPM approx. 4000-4500 RPM as well as at high RPM, approx. 8000 RPM.

For cars manufactured from week 39, 2001 inclusive

Normal RPM approx.5000 RPM as well as at high RPM, approx. 8000 RPM.

Derived combustion fan speed, value

Measurement range 0 - 8000 RPM.

Displays the theoretical speed that the fan should have.

Degree of modulation of combustion fan, value

Measurement range 0 - 100 %.

Reading of the degree of pulse width modulation that the combustion fan is controlled by.

Fuel pump frequency, value

Measurement range 0-10 Hz.

Reading off the pump frequency of the fuel pump.

For cars manufactured up to week 38, 2001 inclusive: In status no. 2 the pump operates at 4.9 Hz for diesel and 5.5 Hz for gasoline.

Cars manufactured from week 39, 2001 inclusive: In status no. 2 the pump operates at 5.7 Hz for diesel and 6.8 Hz for gasoline.

In status no. 3 the pump is controlled by the water temperature. In status nos. 4 and 7 the fuel pump is switched off (0 Hz). The fuel pump is not active in status nos. 1, 7, 5, 6 or 8.

Degree of modulation of Glow plug, value

Measurement range 0-100%.

Reading of the degree to which the glow plug is activated.

For cars manufactured up to week 38, 2001 inclusive

In status no. 1 the glow plug is supplied completely (100%) or pulsed with the frequency 1 Hz. The degree of modulation of the glow plug depends on the voltage.

For cars manufactured from week 39, 2001 inclusive

In status no. 1 the glow plug is supplied completely (100%) or pulsed with the frequency 10 Hz. The degree of modulation of the glow plug depends on the voltage.

Flame monitor, value

Measurement range: 0-5 V.

Reading out flame monitor's voltage.

The flame monitor registers the light intensity in the heater and is used to detect if there is a flame or not. The lower the light intensity that the flame monitor detects, the higher the voltage to the control module. The higher the light intensity that is registered, the lower the voltage.

The following applies when the control module uses the signal from the flame monitor to decide if there is a flame or not

1. If voltage is higher than approx. 2.5 V for a certain time, the control module considers that there is no flame.
2. If voltage is lower than approx. 2.5 V for a certain time, the control module considers that there is a flame.

Extended X-supply, status

Indicates whether the ignition is on or off according to the control module.

Supply voltage to components, status

Indicates whether the control module is sending supply voltage to the combustion fan, fuel pump and water pump.

On: Voltage

Off: No voltage

Glow plug, status

On: Glow plug activated.

Off: Glow plug not activated.

In status 1 the glow plug is on. In status 2 the glow plug is switched off when a flame is detected. Other statuses the glow plug is off.

Water pump, status

On: Water pump activated.

Off: Water pump not activated (status 6, 9 and 10).

Fuel level, status

Fuel level OK: The control module registers that there are more than 4 liters of fuel in the fuel tank and the heater can be started.

Fuel level too low: The control module registers that there is less than 4 liters of fuel in the fuel tank and the heater cannot be started.