2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

[bmdubya1198]

Ha, last S60R I found in a junkyard still had the battery CONNECTED! Good thing the battery was totally dead!

[volvolugnut]

Changed out the fuel pumps today. The donor car at the PYP yard was full of fuel. They better hope the EPA does not find that. That is the same car I found the battery in. Somebody in their prep area is cutting corners.

Snort Snort!

Thanks for the update. Fascinating!

volvolugnut

[RickHaleParker]

Good thing the battery was totally dead!

Did you take it home and play god? You know ... bring dead things back to life.

[bmdubya1198]

Did you take it home and play god? You know ... bring dead things back to life.

Lol, only did that with a genuine Volvo H6 battery I found for my S70. Couldn't get the trunk open without crawling through the lake in the trunk.

[RickHaleParker]

Couldn't get the trunk open without crawling through the lake in the trunk.

No lost. You don't want a battery that been submerged in a lake. The electrolyte and the water would exchange through the vent. The contaminants in the water would seriously mess up the chemical balance of the battery. Same effects as topping off a FLA battery with tap water or bottled drinking water.

[bmdubya1198]

No lost. You don't want a battery that been submerged in a lake. The electrolyte and the water would exchange through the vent. The contaminants in the water would seriously mess up the chemical balance of the battery. Same effects as topping off a FLA battery with tap water or bottled drinking water.

Oh yeah, I wouldn't have touched it. Lord knows what that battery had been through just sitting there in a leaking trunk.

[RickHaleParker]

5. Two mystery harness that dive under the car at the Fuel pumps. The XC90 harness does not have any corresponding connector. I think I'll wait until I fire up the network and see that it tells me.

Figured out the two.

1. On the right side the harness goes to the S60 PEM mounted on the tank. The XC90 PEM is under the seat.
2. On the left side the harness is the 4C and level sensors.

Found a third mystery harness that dives under the car. Connectors fit together but on the XC90 there are two CAN bus lines. On the S80 side it just plain wires The connector does not show up in the S60 OR the XC90 EWDs. It does not look like a match up.

[RickHaleParker]

Got most of the wiring done and control modules changed. Chipping away at the bugs. I reckon Yagger will need to edit the configuration file in the CEM to clear up some of these. I will clean it up as best I can before turning it over to Yagger.


Initial State 10/13/2020 3:13:24 PM
Control Module -Diagnostic Trouble Code Status
AUD-000E Microphone input Signal missing DTC is found active.
Not installed. Missing from donor.

Self test:
BPM No fault found
ICM No fault found
PDM No fault found
PSM No fault found
RDAR No fault found
DIM No fault found

CCM-0070 Configuration fault Faulty identification DTC is found active.
CCM-0071 Damper motor Faulty position DTC is found active.
I suspect problem is missing units on the lin bus. Specifilcy SHM. The S60R seats do not have SHMs.


CEM-1A52 Communication with DDM control module Signal missing DTC is found active.
CEM-1A5E Communication with SAS control module Signal missing DTC is found active.
CEM-1A61 Communication with TCM control module Signal missing DTC is found active.
CEM-1A64 Communication with AOC control module Signal missing DTC is found active.
CEM-1A67 Communication with HCM control module Signal missing DTC is found active.
I suspect the CAN BUS is being corrupted by the 250 kps DDM on the 500 kbs LS CAN bus. Will try disconnecting the DDM and see if this clears up. DEM is a 250 kbps version on a 500 kbps LS CAN, not connected at this time


CEM-2F02 Seat track sensor, driver Signal too low DTC is found active.
CEM-2F05 Seat track sensor, passenger Signal too low DTC is found active.
2004 S60R seats do not have seat track sensors.

CEM-6C48 Transponder type Faulty signal DTC is found active.
Need keys and remotes programed.

CEM-8F12 CEM Beam adjustment Signal too low DTC is found active.
Not installed S60R does not have active headlights.

CEM-9C03 Antenna/light ring Signal missing DTC is found active.
Look into this later.

CEM-DD31 Communication with LCM control module Signal missing DTC is found active.
CEM-DD32 Communication with RCM control module Signal missing DTC is found active.
S60R does not have BLIS, so no left and right cameras installed.


DDM-E003 Configuration fault Faulty configuration DTC is found active.
2004 250 kbps version installed 500 kbs LS CAN BUS. Had the same problem on the PDM. Replaced with a 500 kbs version. Problem solved. No local source for a used 500 kbps DDM.


IAM-1001 Antenna AM/FM Signal missing DTC is found active.
Look in to this later.


REM-8D12 Brake lamps (LED) Signal too high DTC is found active.
Fixed. Routed XC90 3rd brake light harness from trunk to the 3rd brake light.


REM-8F11 Position sensor xenon lamp Signal too low DTC is found active.
S60R has no active headlights.

SRS-0221 CAN signal DTC in CEM DTC is found active.
SRS-0222 CAN signal DTC in CEM DTC is found active.
SRS-DD10 Control module communication Faulty communication DTC is found active.
See DDM-E003 above.

UEM-0004 Siren Communication fault DTC is found active.
Need to connect Siren.


Conclusion Fault found by the DTC Test during previous operation cycle. The DTC Test was not completed during current operation cycles. The condition for completion is not fulfilled.
Current operation cycle, Status Yellow = DTC Test not completed any time during current operation cycle.
Previous operation cycles, Status Red = The DTC Test completed at least once during previous operation cycles and fault found.


Status identifiers
Test is running now No
Test has been completed No
Pending fault is present now Yes
Pending fault has been present Yes
Warning lamp has been switched on Yes
Test is inhibited Yes
Status counter -current value 9
Status counter -maximum value 9

Frozen values from initial readout
Engine Running No
Global Time 28.12 Months
Cabin temperature 30 °C
Ambient Temperature 28 °C
Voltage of battery, CEM 11.8 V
Distance 16711162 km

CCM-0070 Configuration fault Faulty identification
General status Status identifiers
Conclusion Fault found by the DTC Test during current operation cycle.
Current operation cycle, Status Red = The DTC Test completed at least once during previous operation cycles and fault found.
Previous operation cycles, Status Red = The DTC Test completed at least once during previous operation cycles and fault found.

Counter 1 0 Started operation cycles since fault was last found.
Counter 3 1 All operation cycles since the fault was found the first time.
Counter 4 2 Confirmed operation cycles with active fault.

Test is running now Yes
Test has been completed Yes
Pending fault is present now Yes
Pending fault has been present No
Warning lamp has been switched on Yes
Test is inhibited No
Status counter -current value 1
Status counter -maximum value 1

Frozen values from initial readout
Engine running No
Cabin temperature 28 °C
Ambient temperature 28.75 °C
Voltage of battery, CEM 11.88 V
Distance 84986 km

LIN 1, defroster Not mounted
LIN 1, defroster Not Expected

LIN 1 recirculation Not mounted
LIN 1 recirculation Not Expected

LIN 1, temperature left Not mounted
LIN 1, temperature left Expected

LIN 1, temperature right Not mounted
LIN 1, right seat heater Not Expected

LIN 1, air distribution Not mounted
LIN 1, air distribution Expected

LIN 1, left seat heater Not mounted
LIN 1, left seat heater Expected

LIN 1, AQS Not mounted
LIN 1, AQS Not Expected


LIN 2, defroster Not mounted
LIN 2, defroster Expected

LIN 2, recirculation Not mounted
LIN 2, recirculation Expected

LIN 2, temperature left Not mounted
LIN 2, temperature left Not Expected

LIN 2, temperature right Mounted
LIN 2, temperature right Expected

LIN 2, air distribution Not mounted
LIN 2, air distribution Not Expected

LIN 2, left seat heater Not mounted
LIN 2, left seat heater Not Expected

LIN 2, right seat heater Not mounted
LIN 2, right seat heater Expected

LIN 2, AQS Mounted
LIN 2, AQS Expected

[RickHaleParker]

Got the shifter straighten up today. After adjusting the cable it would not go into drive. At first I thought the throw length on the S60 shifter was to short for the TF80 but that did not make sense because the 2006 & 2007 S60R was equipped with a TF80. Turns out there are two different levers for the gear selector on the transmission. The short one matches the shifter throw on the P2 S60, S70 & S80. The long one matches the throw on the P2 XC90.

Turning cold here. Looks like I will need to tarp the project before long and pick it up again next spring.

[RickHaleParker]

Yagger do you think you will be able to clean up the software when I get the hardware finished? Will I need to get a second morgage on my house to pay for it?

This is the XC90 electronics in the S60R V8 conversion.

XC90 S60R -2011 2004 -B6324S5 B8444S

VIN: YV4952CZ6B1605049

Printed by: Rick H Parker US

11/3/2020
--
VDASH v.2.5.215

Mileage: 84 986 km Next service in: 1/2/2021
Last service: 73 904 km / 1/8/2020
Mileage by other ECUs -

DTCs

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CEM-DD31 -Communication with left camera module (LCM). No signal
CEM-DD32 -Communication with Humidity Sensor (HUS) Signal Missing
CEM-2F02 -Seat position sensor, driver. Signal too low
CEM-2F05 -Seat position sensor, passenger. Signal too low
CEM-9C03 -Antenna / light ring. Signal missing
CEM-1A52 -Communication with the driver door module (DDM). Signal missing
CEM-1A64 -Communication with the differential electronic module (DEM). Signal missing
CEM-4A37 -Fuel level sensor. Short-circuit to supply voltage or open-circuit
CEM-8F2C -Windshield wiper. Signal too high
CEM-6C48 -Transponder type. Faulty signal

Notes:
LCM & RCM no BLIS on the S60R mirrors. Delete BLIS from configeration. Task for Yagger.
Humidity Sensor .... trouble shoot.
Seat position sensor. S60R seats do not have Seat position sensors. Delete from configeration. Task for Yagger.
Antenna / light ring. Signal missing. But a new light bulb in Antenna ring.
Driver door module (DDM). Not installed the XC90 DM is a 250 kbs unit. Need to find and replace with a 500 kbs unit.
Fuel level sensor. Check wiring harness in fuel tank.
Windshield wiper has not been installed but too high? Look like a short between the supply voltage and the signal.
Transponder type. New keys and remotes need to be programed. Task for Yagger.


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ECM-P011300 -Intake Air Temperature Sensor 1 Circuit High (Bank 1). General Failure Information. No sub type information
ECM-P010200 -Mass or Volume Air Flow A Circuit Low. General Failure Information. No sub type information
ECM-P046200 -Fuel level sensor A circuit low input signal. General malfunction information. No information on malfunction type
ECM-P170900 -Parking/neutral position switch outside self-test range. General malfunction information. No information on malfunction type
ECM-P126000 -Theft Detected, Vehicle Immobilized. General Failure Information. No sub type information
ECM-P069100 -Fan 1 Control Circuit Low. General Failure Information. No sub type information
ECM-U041886 -Invalid Data Received From Brake System Control Module. Bus Signal / Message Failures. Signal invalid

Notes:
Intake Air & MAF .... I think this is intergrated in the MAF which was disconneccted when this scan was done.
Fuel level sensor .... Trouble shoot. May of knocked the connector around getting the XC90 gear in the S60R tank.
Parking/Netural ? TF80 from 2011 XC90, Lever on gear selector, cable and shifter is from S60R. Shifter and Gear select appear to be in sync.
Theft dectected. Resync ECM and CEM. Task for Yagger.
Fan 1 Not connected.
Brake system is currently a mess. See BCM section below.

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TCM-P061400 -ECM / TCM Incompatible. General Failure Information. No sub type information

Notes:
ECM & CEM not synced the two came from different XC90s.

------------------------------------------------------------------------------------------------------


BCM-C003401 -Right front wheel module. General Failure Information. General electrical failure
BCM-C002201 -Brake Booster Solenoid. General Failure Information. General electrical failure
BCM-C004501 -Brake pressure sensor "B". General malfunction information. General electrical malfunction
BCM-C004401 -Brake Pressure Sensor "A". General Failure Information. General electrical failure
BCM-C004801 -Brake Booster Travel Sensor. General Failure Information. General electrical failure
BCM-U011400 -Failed communication with differential electronic module (DEM). General malfunction information. No information on malfunction type

Notes:
This is going to be a PITA!
Space is to tight that the only way to get to the BCM is to disconnect the hydraulic lines and remove the whole assembly.
BCM is from a different truck. A 2006 XC90.
A rear brake hose is split.
Both connectors to the Brake Booster need replaced. Plastic clips are broken.
Space to tight to get harness to master cylinder connected. Might be able to take fender liner out and get to it from bottom.
Sensors on the S60R brake booster may not be compatable with the XC90 software.
DEM see DEM above.

Fix connectors, replace brake hose. bleed brakes then see where its at. Hope Yagger can sort out the software.

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ICM-E003 -Configuration fault. Faulty configuration

Notes:
Most likely a communcation problem. Fix the other CAN problens then coome back to this.

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CCM-0071 -Damper motor. Faulty position
CCM-0070 -Configuration fault. Faulty identification
CCM-DD12 -Left seat heater. No communication
CCM-DD30 -Right-hand seat heater. No communication
CCM-DD16 -Damper motor air distribution. No communication
CCM-DD31 -Recirculation damper motor. No communication
CCM-DD22 -LIN bus 2. Incorrect check sum
CCM-DD02 -LIN bus 1. Incorrect check sum

Notes:
No seat heaters on S60R seats. Delete from configeration. Task for Yagger.
Three of the damper motors are physically identical. Most likely got two in the wrong postition.
Try swaping distribution with Recirculation.

-------------------------------------------------------------------------------------------------------


REM-8F13 -Bi-Xenon lamp position sensor. Calibration fault
REM-8F11 -Xenon lamp position sensor. Signal too low

Notes:
S60R Bi-Xenon headlights installed Rem is expecting the XC90. Lamp does not move on high beam. Solution TBD.

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SRS-DD10 -Communication control module. Faulty communication
SRS-0221 -CAN signal. Diagnostic trouble code (DTC) in the central electronic module (CEM)
SRS-0222 -CAN signal. Diagnostic trouble code (DTC) in the central electronic module (CEM)

Notes:
Work out the other CAN BUS issues then come back to this.

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UEM-0004 -Siren. Communication fault

Notes:
Most likely leaking battery in the Siren.

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IAM-1001 -AM/FM antenna. No signal

Notes:
Try rerouting wiring and powered amp to right side attenta. Put passive attenta on left side.

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AUD-000E -Microphone input. Signal missing

Notes:
Microphone not installed. Phone Blue Tooth is installed and working. Mic was missing from donor.
find another one
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HCM-U012987 -Lost Communication With Brake Control Module. Bus Signal / Message Failures. Missing message
HCM-U1A3887 -Lost Communication With Left Headlamp Module. Bus Signal / Message Failures. Missing message
HCM-U1A3987 -Lost Communication With Right Headlamp Module. Bus Signal / Message Failures. Missing message

Notes:
S60R headlight installed does not have active headlights. Delete from configeration. Task for Yagger.

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Hardware and software numbers.

MOD | Hardware # --| Software #1 ---| Software #2 ---| Software #3 ---| Software #4 --|
------|------------------|-------------------|-------------------|--------------------|------------------|
CEM | 000031394157 | 000031394162 | 000031376480 | 000031394165 | ----------------- |
DIM | 000031296344 | 000031376463 | 000031343999 | 000031270031 | 000031254545 |
ECM | 000030729999 | 000030788536 | 000030785519 | ---------------- | ------------------ |
TCM | 000030735597 | 000030788417 | 000030759569 | ---------------- | ------------------ |
BCM | 0030714960 A | 000030667825 | 000030667476 | ---------------- | ------------------ |
ICM | 000031300029 | 000031310182 | 000030752429 | 000031328768 | 000031310632 |
PDM | 000030658698 | 000030732810 | 000030669939 | ---------------- | ------------------ |
CCM | 000030782505 | 000031346858 | 000030782259 | ---------------- | ------------------ |
REM | 000031314469 | 000031376468 | 000031394838 | 000031327887 | ---------------- |
SRS | 000031295112 | 000031313172 | 000030737507 | ---------------- | ------------------ |
UEM | 000008676986 | 000030644819 | 000030765601 | 000030772593 | ---------------- |
SAS | 000030798581 | 000031313882 | 000031313888 | ---------------- | ------------------ |
PSM | 000008691708 | 000030710363 | 000008697219 | ---------------- | ------------------ |
IAM | 000031285830 | 000031328061 | 000031337284 | ---------------- | ------------------ |
AUD | 000031310002 | 000031310009 | 000031215664 | ---------------- | ------------------ |
BPM | 000031310740 | 000031310741 | 000031328394 || ---------------- | ----------------- |
HCM | 000030667609 | 000030782607 | 000030782042 | ---------------- | ------------------ |
DDM | 250 kbs DDM on a 500 kbs bus. Need to locate a P2 500 kbs DDM -------------------|
DEM | 250 kbs DEM on a 500 kbs BUS. Upgrade when rear differental is replaced . ------|
MP2 | Option not installed. Missing from doner XC90. -----------------------------------------|
AUU | Option not installed. Missing from donor XC90. ----------------------------------------|