Installation Instructions for T-Connector Adapter for Volvo XC60

Part Numbers:

• 118739

Tools Required:

• Trim Panel Remover
• 10mm Socket & Ratchet or 10mm Wrench
• Drill (3/32” Drill Bit)
• 1/4” Socket
• Wire Crimpers
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe

Step-by-Step Instructions:

1. Prepare the Rear Cargo Area:

   • Open the tailgate and remove the cargo floor door.
   • Carefully remove the floor trim panels and access panels on both sides of the vehicle.
   • Set aside all items to avoid damage.

2. Locate the Taillight Wiring Harness:

   • On both the driver and passenger sides, locate the vehicle’s taillight wiring harness inside the access panel area.
   • Disconnect the connectors, ensuring not to break the locking tabs.
   • Clean all connector surfaces to remove dirt.

3. Install the Driver-Side T-Connector:

   • Insert the T-Connector end with the yellow wire between the driver-side taillight wiring connectors.
   • Ensure all connectors are fully inserted and locked into place.

4. Route the Passenger-Side T-Connector:

   • Route the T-Connector harness with the green wire from the driver’s side trim panel under the threshold to the passenger-side taillight pocket.
   • Repeat step 3 for the passenger side using the T-Connector end with the green wire.

5. Ground the White Wire:

   • Locate a suitable grounding point on the driver’s side near the connectors.
   • Drill a 3/32” hole and secure the white wire using the provided eyelet and screw.

   Caution:

   • Verify what is behind any surface before drilling to avoid damage or injury. Do not drill into exposed surfaces.

6. Connect the Power Wire:

   • On the driver’s side, locate the black 12-gauge power wire from the T-Connector box.
   • Attach the provided black 12-gauge wire to the power wire using the provided butt connector.
   • Route the black wire along the vehicle’s frame or existing wiring into the engine compartment and up to the battery.

7. Connect to the Vehicle Battery:

   • Disconnect the vehicle’s negative (-) battery cable.
   • Attach the ring terminal to the fuse holder and connect it to the vehicle’s positive (+) battery cable.
   • Connect the other end of the fuse holder to the black wire using the yellow butt connector.

   Warning:

   • Follow all warnings printed on the vehicle’s battery. Avoid routing wires near hot pipes, heat shields, or moving parts.

8. Reconnect the Battery:

   • Reconnect the vehicle’s negative (-) battery cable.
   • Insert the 15-amp fuse into the fuse holder.

9. Mount the T-Connector Black Box:

   • Locate a flat surface in an out-of-the-way place and mount the black box using the provided double-sided tape.

10. Reassemble the Vehicle:

    • Reinstall the access panels, floor trim panels, and cargo door.
    • Ensure no wires are pinched or damaged during reassembly.

11. Test the Installation:

    • Test and verify the installation using a test light or trailer.
    • Reset the vehicle’s electrical system by temporarily removing the key from the ignition.

    Specifications:

    • Max. stop/turn light: 1 per side (2.1 amps)
    • Max. tail lights: (5.6 amps)

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the towing manufacturer’s rating or the specified maximum circuit ratings.
• Always wear safety glasses and follow safety precautions during installation.

Manufacturer Notes:

• Store the 4-flat connector in the spare tire compartment when not in use.
• Refer to the vehicle owner’s manual for additional guidance.

Installation Instructions for 4-Way to 7-Way Adapter and Brake Control Wiring

Tools Required:

• Phillips Head Screwdriver
• Drill with 3/32" Drill Bit
• 10mm Socket & Ratchet or Wrench
• Wire Crimpers
• Wire Cutters
• Test Light or Multimeter
• Cable Ties

Part 1: Install the 4-Way to 7-Way Adapter

Step-by-Step Instructions:

1. Mount the Adapter:

   • Choose a suitable mounting point on the vehicle, typically near the hitch.
   • Use the provided bracket and screws to secure the adapter.

2. Connect the 4-Flat Plug:

   • Plug the 4-flat connector on the adapter into the existing 4-flat plug on the vehicle.
   • This connection enables tail lights, left turn, and right turn signals.

3. Ground the Adapter:

   • Locate a clean, solid grounding point near the adapter.
   • Drill a 3/32" hole if necessary and secure the white ground wire from the adapter using the provided screw and eyelet.

4. Leave Additional Wires Disconnected:

   • The following wires will remain disconnected until Part 2:
     • Black Wire: Power from the battery.
     • Blue Wire: Brake control output.
     • Yellow Wire: Reverse light (optional; leave disconnected unless needed).

5. Test Initial Connection:

   • Use a test light or trailer to verify functionality of the 4-way connections (tail lights, turn signals).

Part 2: Install Brake Control Wiring

Step-by-Step Instructions:

1. Mount Circuit Breakers:

   • Install two 30A circuit breakers on the firewall or another suitable location near the battery.
   • Use self-tapping screws to mount them securely.

2. Route Power Wires:

   • Connect the black 12-gauge wire from the 7-way adapter to the auxiliary side of one circuit breaker (this powers the 7-way socket).
   • Run a heavy-gauge wire from the battery's positive terminal to the battery side of this circuit breaker, using a ring terminal.
   • Run another heavy-gauge wire from the battery's positive terminal to the auxiliary side of the second circuit breaker (for the brake controller).

3. Install the Brake Controller:

   • Mount the brake controller under the dash on a firm surface.
   • Use the following connections:
     • Red Wire: Connect to the cold side of the brake switch (active only when the brake pedal is pressed).
     • Blue Wire: Connect to the blue wire on the 7-way adapter for trailer brakes.
     • White Wire: Connect to a solid ground point on the vehicle body.
     • Black Wire: Connect to the auxiliary side of the second 30A circuit breaker (provides power to the brake controller).

4. Optional: Connect Reverse Light Circuit:

   • If the trailer has a reverse light circuit, connect the yellow wire from the 7-way adapter to the vehicle’s reverse light circuit.

5. Reconnect the Battery:

   • Reattach the negative battery cable and ensure all connections are secure.
   • Insert the fuses into both circuit breakers.

6. Secure All Wires:

   • Use cable ties to secure all loose wires and prevent damage or rattling.

7. Test the System:

   • Verify functionality of all circuits (running lights, turn signals, brake lights, and brake controller output).
   • If applicable, test the reverse light circuit.

Notes:

• Most installations will only require connecting the black and blue wires from the 7-way adapter.
• Leave the yellow wire disconnected unless the trailer has a reverse light or surge brake lockout circuit.
• Always adhere to safety guidelines and verify all connections before use.

Warning: Incorrect wiring can cause damage to the vehicle or trailer. Test all connections carefully before use.