S40 and V50 Boost Gauge Install
Special Thanks To: Cicatriz
Tools Needed:

Zip-Ties Razor
Wire Tap
 Coat Hanger
Wire Loom
 Screw Driver
Take off the engine cover and locate the line coming off the intake manifold. It's a thick black vacuum line.  Once you have located it using a razor cut it in the location marked in red below.
Boost Line
Once the line is tapped, run the boost line along the bottom side of the engine cover as pictured below (I used some zipties to hold it in place).
S40 Battery Cover

Remove the battery cover.  Now run the line through the hole on the left side of the battery cover, into the compartment that holds the battery and around the backside of the battery.

S40 Battery
From the inside with someone standing by the battery cover guide the line down into the cabin.  Have someone push a wire hanger up through the clutch plate opening in the cabin, and use that to draw the line down into the cabin.

It should come out of here (you can poke a hole in the rubber stopper that plugs it up and run the line through that).

Clutch pass through

Once you have the line through, pull it so you have enough slack to run it up the steering column plastic shroud underneath. Push it below the shroud and push it up until you can see it next to the uppermost part of the steering wheel.  

Boost Gauge


To wire the boost gauge remove the side plastic piece by placing your fingers in the black rubber stopper and pulling hard.

gauge wiring

With the vent guide out of the way you can now remove the trim piece.

S40 Volvo Gauge

Next turn you attention to the headlight switch.  Place your fingers behind the light switch panel and push it outward until it pops out of place.

gauge hook up

I used a wire tap to wide the gauge.  You need to tap the 3rd orange wire down on the left most side of the connection. Be careful not to rip the wires from the connector when pulling them apart from the bundle as they are taped together.

Now you can run the wire back around the steering shroud as I did with the boost gauge.  The electrical wire will be a bit more hidden because it can go sideways through the inside of the plastic as opposed to directly underneath.

Connect all related wiring.  For the ground use the metal underneath the carpet next to the center console. Just pull the carpet out a bit and ground it there.

Sv0 Volvo boost gauge installed

Finished!
Project S60
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