General Information - Design and Function: Other Volvo S80 I

Fuses, relays

There are fuses and relay in three central electrical units in the car

1. at left rear edge of the engine compartment.
2. in the passenger compartment on the left-hand side of the dashboard, accessible from the outside.
3. in the cargo compartment on the cargo compartment, positioned around the rear electronic module (accessible from underneath via the soundproofing panel).

Main fuses are in the central electrical units in the engine compartment and cargo compartment.

All the relays are normal standard relays without "intelligence" (without integrated electronics) The relays are in three sizes - mini, standard and maxi.

Most mini relays have the relay coil directly connected to the printed circuit board in the central electrical unit. On other relays (standard and maxi) the relay coil is most often connected to the printed circuit board via the cables.

Starter system

There are 5 different versions of starter motor, including a completely new starter motor for 4T65 EV/EV-GT. Others are C/O X70 (depending on engines and markets).

Battery, charging system

The battery is located low at the rear of the cargo compartment. To prevent the hydrogen gas build up in the cargo compartment there is an evacuation hose which routes any gas out into fresh air.

The terminal for the starter cables is in the engine compartment (left shock absorber mounting).

Central locking and alarm

The functions are nearly exactly the same as for the VGLA in the S/V70.

The differences are

1. The button in the center console for: connecting/disconnecting the alarm sensors (mass movement and tilt sensors) and temporary disconnection of the deadlock function.
2. Button in the center console for privacy lock on the tailgate. (In activated position the tailgate can only be unlocked and opened using the car master key.)

Remote control - shape, buttons and functions

Button for locking/activating alarm.

Button for deactivating alarm/unlocking the car.

On cars with power drivers seat with memory there is also the possibility of a personal remote control to automatically set the drivers seat and door mirror positions to preprogrammed positions (memory position 1, 2, or 3). The function is activated by pressing UNLOCK and opening the drivers door (the door must be opened within 5 minutes).

Button for unlocking/opening the tailgate.

The alarm is automatically connected as long as the tailgate is open.

Button for local lighting (=parking lamps, interior lighting, license plate lighting and optional door mirror lights). Lights an area of at least 5 meters around the car. By pressing the yellow button the lighting is lit for 30 seconds (programmable to 60 and 90s). The lighting goes out when the button is pushed again, if the time has expired or if the ignition is switched on. It can be relit by pressing again but for only 90 seconds during a 10 minute period.

Remote control, general

The remote control has rolling random codes.

1. Automatic locking at 5 km/h (3 mph) (market dependent, programmable).
2. Automatic unlocking in event of collision - signal from SRS (market dependent, programmable).
3. It is possible to program up to 6 remote controls.
4. A panic alarm is not permitted on the remote control, it must be activated from the inside the car (to prevent misuse)

Immobilizer

System description

The Immobilizer contains the Central Electronic Module, Engine Control Module (ECM), Driver Information Module and Immobilizer Antenna Unit.

The Immobilizer Antenna Unit is connected to the Central Electronic Module via two cables with serial communication one of which contains the immobilizer clock signal and the other contains the Immobilizer Data Signal.

Functionally the system is divided into two

1. Transponder check via Central Electronic Module, Immobilizer Antenna Unit and transponder.
2. Immobilizer check with Central Electronic Module, Engine control module (ECM) and Driver Information module.

Both checks are activated when the ignition is switched on.

The transponder check is controlled by the Central Electronic Module. Central Electronic Module carries out a transponder check by communicating with the transponder via the Immobilizer Antenna Unit.

The immobilizer check also consists of a communication between the Central Electronic Module and Engine control module (ECM) to check the VIN and Immobilizer PIN codes in the units.

The VIN code is unique and is self programming in the engine control module (ECM).

It also includes the result from the transponder check. The communication occurs in the CAN high speed network.

If the checks are OK, the engine control module (ECM) permits the engine to start by sending an approval signal to the central electrical module which connects the starter relay to the starter motor.

Communication with the Driver Information Module only takes place if one or both the checks is not OK.

Transponder

In the key there is a transponder which is a passive component. The same type of codes as in the S/V 70 are stored in the transponder (security code, key code or transponder ID). The security code is stored in VITAL (a new database replacing QW 90), while the key codes are only stored in the central electronic module. When replacing the central electrical module all the codes except the key codes are obtained in VITAL and programmed into the central electrical module, which then has the same codes as the old one. Because the key security code, stored in VITAL, is also programmed into the new Immobilizer in the central electrical module, the new central electrical module will recognize the keys as soon as the keys are programmed with the key codes. Each of the keys must be programmed into the central electrical module.

Immobilizer antenna unit

The immobilizer antenna unit is located on and beside the ignition switch. (8097 C/R) There is communication between the immobilizer antenna unit and the central electrical module via two cables and antenna communication between the immobilizer antenna unit and the transponder.

The function of the immobilizer antenna unit is to modulate/demodulate (modify the carrier wave) and send/receive.

A digital code is received from the Central Electrical module which modulates the sending frequency and sends it to the transponder. The transponder replies by sending a distorted signal containing the key code, security code and the randomly selected code. These are demodulated and sent to the central electrical module.

ECM

The engine control module (ECM) communicates with the central electrical module on the CAN high speed network.

When the ignition is switched on the engine control module (ECM) starts an immobilizer check.

The engine control module (ECM) transmits a calculated code to the central electronic module. The engine control module (ECM) receives/checks the central electronic module response code and transmits an approval to the central electronic module.

If the checks are approved the engine can start.

Central electronic module

The central electrical module communicates with the engine control module (ECM) on the CAN high speed network, with the Immobilizer antenna unit via a two way serial communication and with the DIM on the low speed network. When the ignition is switched on the central electrical module starts a transponder check. The central electrical module calculates the awaited answer and compares it to the answer received from the transponder. The central electrical module only permits the engine control module (ECM) to start the engine if the calculated and received response are the same. The central electrical module and the engine control module (ECM) are recognized in an immobilizer check by exchanging calculated codes and comparing them. The central electrical module checks the engine control module (ECM) code and sends a reply which contains the information about the transponder check. If the immobilizer check is not OK, the central electrical module transmits a signal on the low speed network to the driver information module with information about the fault.

The immobilizer function (that the car cannot be started) is activated when the ignition is switched off and the key removed from the lock.

DIM

The Driver information module communicates with the central electrical module on the CAN low speed network. When the ignition is switched and neither of the previously mentioned checks are approved the Driver information module receives information from the central electrical module and displays a diagnostic trouble code (DTC) on the combined instrument panel display.

Scheme 13

Compared to the X70 the P2X has a more developed network which covers most functions in the car.

The electrical system is based on a network with a number of modules. The data is digitally transferred, between the modules, via the usual twinned cables (twisted pair).

The communication method is multiplex and the communication protocol is VOLCANO. (VOLCANO is a further development of CAN and operates with real time operation and prioritizing).

The power supply to the modules occurs in the normal way using the usual cables.

Transmitters (sensors, switches etc.) are connected directly to the modules via the usual cables.

Controlled components are connected directly to the modules or via the usual cables. They are controlled by the modules directly or via the relay/power stages etc.

The electrical system status is continuously monitored. In case of faults/problems, manual deselection of functions etc., the driver is informed via check/warning lamps and text messages in the display.

High and low speed sectors

The network consists of two sectors with different transfer rates.

1. The engine compartment sector, which requires fast communication, has a transfer rate of 250 kbps.
2. The passenger compartment sector, which does not require such fast communication, has a transfer rate of 125 kbps.

The connection of these two sectors is provided by the Central Electronic Module which converts the communication between the network sectors up or down.

For example instrument/control lighting

Previously the control and instrument lighting intensity has been directly controlled by the rheostat position via separate cables to each of the lights.

In the P2X the rheostat is connected to the network through the Light Switch Module (LSM) and communication takes place as follows

1. Light Switch Module (LSM) senses rheostat position and informs the Central electrical module using serial communication.
2. The Central Electronic Module controls the lighting for the hazard warning signal flasher and front and rear cigarette lighter.
3. The Central Electronic Module sends the information onwards as a CAN message on both high and low speed network sectors.
4. The Transmission Control Module (TCM) reads the CAN message on the high speed sector and sends the message on to the Gear selector module by serial communication. The Gear selector module controls the gear lever lighting.
5. The CAN message is received by the Upper Electrical Module (UEM), Drivers Door Module (DDM), Passenger Door Module (PDM), Road Traffic Information (RTI), Phone Module (PHM), Driver Information Module (DIM), Audio Module (AUM) and Climate Control Module (CCM) which all adjust the lighting intensity according to the rheostat position.

Control panel lighting

The control panel lighting is affected by the light conditions by the climate control system sun sensor senses the light sensitivity, which affects the climate control system setting.

Information about the light intensity is converted in the climate control system module to a CAN message which is sent out on the network and received by the other modules. The control panel lighting is adjusted depending on the light intensity, so that it is stronger in daylight and weaker when it is dark.

Scheme 14

4T65-EV, EV-GT is a 4 speed, electronically controlled automatic transmission with torque converter lock up function. The transmission has been developed by General Motors (GM) for the Volvo 6 cylinder engine. On the AW transmission the two shafts are connected to drive, on the new transmission the two shafts are connected with a double chain. This version means that the transmission is a little larger than previously used automatic transmissions.

The transmission has a torque controlled, adaptable pressure regulation which provides high quality shifting and an increased lifetime.

Like the X70 reactive programming occurs, that is to say that the Transmission Control Module (TCM) senses the drivers style, how fast the accelerator is depressed etc, and adjusts the gear change scheme sensitivity accordingly. Sports driving gives aggressive gear shifting, calm driving gives calm gear shifting. This information is not stored in the Transmission Control Module (TCM).

However the adaptation is stored as the Transmission Control Module (TCM) programs itself, it senses how the transmission behaves and if any interior component wear affects it and using this is able to make the optimal change at every point. This reactive response is continuous while driving.

The adaptation is stored in the transmission control module (TCM) and must be reset at oil and transmission replacement.

The WINTER program remains and is engaged manually using a button beside the gear selector lever.

A display in the speedometer indicates which gear is selected.

General, Gear selector

The 4T65 gear selector assembly is available in two versions, with and without Geartronic. The gear selector assembly has its own micro-processor. The solenoid in the gear selector assembly is connected to the transmission diagnostics. The gear selector assembly has both an active mechanical ignition switch interlock and an electronic ignition switch interlock. The gear selector has 7 different positions.

Geartronic

Geartronic is a manual position with fast changes with the following gear positions: P-R-N-D-MAN.

Four gear shift positions can be selected in manual position. MAN (manual gear shifting) position is selected from D position by sliding the gear selector lever backwards. The gear which was temporarily selected in D is held in position and from here it is possible to shift up and down manually. A spring on the underside of the gear selector lever makes the shifting movement easier and prevents the selector lever from sticking between positions D and MAN.

Kick down will not function in MAN.

The gear selector lever knob is similar to a manual gear lever knob with slender design and a small button.

General M65

The M65 is a five geared, manual transmission supplied for Volvos new six cylinder engine.

The transversely mounted engine requires a very compact transmission. The transmission is extremely short and both the clutch and the space for the flywheel are reduced in size compared to previous models.

The total length reduction is 56 mm compared to the M56.

The M65 has four shafts, as opposed to the 3 shafts used in the M56. The gear movement is divided between two carrier plates.

Brake system

There are only a few differences from the previous system used on the X70.

The Central Electronic Module receives vehicle speed signal from the ABS sensors.

The brake sizes are 15" and 16", but the brake calipers are the same, only different holders. Version/market dependent.

The parking brake is mechanical and integrated into the rear brake discs.

48 tooth mechanical pulse wheel at the front, 48 tooth magnetic pulse wheel rear

Wheel spin monitoring

The monitoring system functions in the same way as for the X70. When one of these systems begins to function the driver is warned by a flashing control lamp and a message in the combined instrument panel display.

New A shaped control arm and control arm mounting

A shaped lower control arm is secured in rubber bushing in the sub frame.

The control arm bushings are differently shaped, the front bushing is axially mounted with low radial torsion, the rear control arm bushing is radially mounted with high radial torsion. This design means that the lateral and lengthways forces are maximally absorbed, giving good driving and comfort standards.

The ball joint is screwed into the steering knuckle.

The steering knuckle has a loose hub (4).

The front and rear suspension geometry is designed to fulfill anti-dive/lift requirements. Negative steering radius.

The only adjustable wheel angle is toe-in.

Note. When changing wheel rim size the steering limiter roll must be replaced (control arm section). The wheel offset is different depending on wheel rim size, 15"= 43 mm (1.77 in), others= 49 mm (1.93 in).

Scheme 15

Rear suspension is the Multi link type.

This type of rear suspension provides good comfort and road holding qualities. The upper and lower struts and the control arms control the wheel movements and allow better lengthwise suspension travel. (Camber angle at the springs)

Toe-in is adjustable at the inner track rod mounting (eccentric screw).

Low build height.

Chassis setting

1. 2 different types of chassis settings
2. Standard and Dynamic. (market dependent)
3. The Nivomat rear shock absorber is available as standard/option on all chassis settings.

Scheme 16

Steering gear

There are two types of steering gear, normal conventional power steering and speed related power steering.

Standard/option depending on variant/market.

Speed Sensitive Steering

The primary task for this system is to ensure that there is high power assistance for the steering when parking and at low speeds. To retain the road feel at higher sped the servo assistance decreases the faster the speed. This is achieved by varying the oil flow in the steering gear.

The oil flow is controlled, based on vehicle speed, by a step motor controlled by the central electrical module.

Stepper motor function

The stepper motor has the capacity to be moved an exact number of steps/rpm. This motor moves 48 steps/engine revolution. There is a conical control piston with an internal thread on the engine shaft which is screwed radially by the stepper motor. The central electrical module monitors the stepper motor position and resets it after every driving cycle.

Controlling power steering assistance

The conditions for activation are that the ignition key is in position 2 and engine speed is above 500 rpm. The signals are transmitted via the central electrical module.

At low speed the following occurs

1. Central electrical module supplies voltage to the stepper motor which begins to regulate, the piston on the rotor shaft moves and opens the return pipe on the steering gear which means that high servo assistance is achieved.

At high speed increase the central electrical module controls the stepper motor so that the position of the piston is changed every 5 km so that the steering becomes stiffer the faster one drives (the return pipe is choked). As speed is reduced the stepper motor reacts at 5 km/h (3 mph) intervals.

The vehicle speed signal to the central electrical module comes from the ABS sensor.

Other

The particle filter is standard and is mounted downstream of the blower fan so that even recirculated air is cleaned. (previously available as an option). Replace at 15,000 Km or every 2 years.

Refrigerant may only be topped up on the high pressure side of the system to avoid the risk of refrigerant entering the compressor.

Scheme 17

Seat belts, front and rear

Seat belts with pyrotechnic seat belt tensioners are standard in all markets.

A new type of terminal connector with a spring lock is used to connect the pyrotechnic pipe to the SRS system.

Drivers airbag

A new type of explosive charge is used. It provides an environmentally friendly, non toxic gas.

A new type of terminal connector with a spring lock is used to connect the airbag pipe to the SRS system

Passenger airbag

The dealership may, at the customers request, install a switch for manually connecting/disconnecting the airbag (the switch is installed under the hazard warning flasher switch).

The airbag status, connected or disconnected, is displayed with two LEDs in the key switch.

SIPS airbag

SIPS airbag with electronic ignition is standard for both front seats.

Side collision sensors

The sensors are located in the B and C posts, this is to obtain a fast/early reaction in case of a side collision.

The sensors are directly connected to the SRS module.

Inflatable Curtain (IC)

1. Inflatable curtains are standard on all cars.
2. The inflatable curtain minimizes the risk of head injury for passengers in both the front and rear outer seats in event of side collisions and multiple point collisions (when the car is in collision from more than one direction at once).

Inflatable curtains consist of inflatable protective curtains on each side of the car. The curtains cover the upper sections of the interior of the car from the A to C post.

The curtain is manufactured using "one piece woven technology" - this means that the curtain is woven in one piece with channels in predetermined places.

WHIPS (Whiplash Protection System)

1. WHIPS is standard for both front seats.
2. The intention of WHIPS is to minimize the risk for whiplash injuries in event of collision from behind. The system is optimized for collisions at low speed (most of this type of accident occur at 10-20 km/h (6 - 12 mph)).

The system is completely mechanical and is integrated into the seats. It consists of six springs with force limiters in the backrest and release mechanisms with break pins, the release mechanisms can move backward and be angled backwards and forwards.

Colors

12 colors will be offered. 3 solid, 9 metallic/pearl colors. There are two new metallic/pearl colors, JAVA pearl and Moondust metallic. All colors are water based.

The underseal is solvent free.

Painted components

The front section the soft nose covering the front bumper and grille, the rear bumper, door mirror cover, roof trim, tailgate plastic panel and exterior door handles are color coded.

Lighting

Headlamps with hardened clear glass. This makes them more resistant to stone chips because there is less tension built into the glass.

There will be a shield on the headlights to prevent the customer from adjusting the horizontal position of the lamp. This applies only to the USA where it is a legal requirement.

Sidemarker lamps, separate at the front, integrated into the rear lamp units at the rear.

Beside the rear license plate there is a security unlocking mechanism which can be used if the central locking does not work.

As an option a bulb may be installed in each door mirror which, together with the interior lighting, parking lamps and license plate lighting, light up as so called approach lights. Activated by the remote control.

When one leaves the car the "guide me home" lighting can be activated using the headlamp flash stalk. The lamps (low beam, parking lamps, license plate lighting and the lamps in the door mirrors) light for either 30, 60 or 90 seconds (programmable).

The well known Volvo emblem has a more modern tone.

Only the driver's door has a door lock, this is of the rotating type.

Windows

The windows are tinted and 4-5 mm (0.16-0.20 in) in thick to reduce the noise level in the car.

Power windows are standard.

Wheel Rims/Tires

WHEEL RIMS/TIRES

Scheme 18

Combined instrument panel

Display for fault/warning/status messages, trip computer and car phone functions. Information is available in 11 different languages (programmable).

Use the Enter button to scroll between the various fault/warning messages.

There are three types of fault/warning/status messages with different grades of severity

A. The fault can be acknowledged and erased only after the fault has been erased.

B. The message must be read off and confirmed before it is erased. Use the Enter button to confirm.

C. The message is only displayed for approximately 10 seconds.

The display for the odometer and two trip odometers.

Short press on the button = shift between the trip odometers.

Long press on the button = reset the selected trip odometer.

The warning lamp may be red or orange when it is lit. One of the other warning lamps may also light at the same time and a message may be displayed.

Red lamp = Stop the car. Read the message in the display.

Orange lamp = Read the message in the display. Remedy as necessary.

Display for the selected gear (automatic transmissions), clock and outside temperature gauge.

Check/warning lamps (cars in the USA have different symbols for a number of the lamps).

Buttons in the center console

Folding the rear head restraint forward.

Cars with electrical folding door mirrors

the door mirror folds in if the button in the center console is pressed in for more than 3 seconds.

Auxiliary lamps.

Engagement/disengagement of the STC function.

Reserve.

Disengagement/engagement of the sensor for the alarm (mass movement and tilt sensors).

Temporary disengagement of the deadlock function (the key must be in position 0 or I).

"Private locking" of the tailgate. When this function is activated, the tailgate can only be unlocked with the master key for the car.

12 V socket

Controls for cruise control (located in the steering wheel)

ON/OFF button.

RESUME - returns to the previously selected speed.

Temporary disengagement of the cruise control (re-engaged the next time the button is pressed).

Entering the desired speed (cannot be engaged if vehicle speed is below 35 km/h). The set speed can be finely adjusted by one or more short presses on + or -. A short press is the equivalent of approximately 1.6 km/h.

Controls in the steering wheel for the audio unit and the car phone

For functions, see the instructions for Audio, RTI and car phone.

Right control stalk

Stalk for control of the windscreen wipers and washers.

Use the ring (marked) to adjust the strokes per time unit for intermittent wipers.

Lighting switch

Front fog lamps

Rear fog lamps

Panel light adjuster

Beam height control

Left control stalk

Enter button. Used to read (confirm) and scroll between the messages in the combined instrument panel display.

Trip computer control: Turn the ring to select the function. The trip computer has four functions - the selected function is displayed in the combined instrument panel display.

1. Range until empty (less than 10 km = "---").
2. Average fuel consumption.
3. Current fuel consumption.
4. Average speed.

RESET - to reset the average fuel consumption and the average speed.

The stalk is also used for: high beam flash, switching between high and low beam, turn signal lamps and activation of the "follow me home" lights. Time controlled activation (90 seconds) of low beam, interior lighting, side marker lamps and the lamps in the door mirrors

Control for adjusting the door mirrors

Two buttons to select the left or right door mirror. The selected mirror is then adjusted with a lever (joystick).

Controls for power windows

The ignition key must be in the radio or drive position before the power windows will operate.

Note. When the ignition is then turned off and the key is removed from the ignition, the windows can be opened and closed, as long as no doors have been opened.

There are two positions for the switches for the front door power windows - manual and auto.

The first position (one click downwards/upwards) = manual opening/closing.

The second position (two clicks downwards/upwards) = auto down/auto up. The auto up function has an integrated anti-trap system - the window opens fully again if anything is caught.

Hazard warning signal flasher switch/airbag disengagement

An additional switch can be connected under this switch. This is to allow engagement/disengagement of the passenger airbag. The engagement/disengagement status is displayed with an LED on the switch. (The switch can be installed by the dealer at the customer's request)

Heated door mirrors, heated rear windshield

Common switch - the heating for the door mirrors and the windshield starts simultaneously.

Timer function - the heating (demisting) is switched off automatically after approximately

1. 6 minutes for the door mirrors.
2. 12 minutes for the rear windshield.

Heated front seats

One switch per front seat.

There are two power positions

1. press the switch once (both the LEDs in the switch light) = full heat.
2. press the switch twice (one LED in the switch lights) = reduced heat.