Installation Instruction

Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
XC60 2019
XC60 (18-) 2019 D4204T14 M66, XC60 (18-) 2019 D4204T4 M66, XC60 (18-) 2019 D4204T14 M66 AWD, XC60 (18-) 2019 D4204T14 TG-81SC, XC60 (18-) 2019 D4204T14 TG-81SC AWD, XC60 (18-) 2019 D4204T23 TG-81SC AWD

Instruction NoVersionPart. No.Click to download PDF-version of this Installation Instruction
314546721.131454669
Electric engine heater and passenger compartment connector




IMG-431860




 

Special tools

 

981 4204 Expander pliers

Tool number:981 4204

Tool description:Expander pliers

Tool boards:87

 

951 2955 Cover

Tool number:951 2955

Tool description:Cover

Tool boards:20

 

981 4192 Hose

Tool number:981 4192

Tool description:Hose

Tool boards:EU99

 

951 2957 Coolant Reservoir

Tool number:951 2957

Tool description:Coolant Reservoir

Tool boards:20


Equipment
IMG-345497
IMG-239664
IMG-240693
IMG-239660

IMG-431681

IMG-432232


 
 

Information

1
 

  • Read through all of the instructions before starting installation.

  • Notifications and warning texts are for your safety and to minimise the risk of something breaking during installation.

  • Ensure that all tools stated in the instructions are available before starting installation.

  • Certain steps in the instructions are only presented in the form of images. Explanatory text is also given for more complicated steps.

  • In the event of any problems with the instructions or the accessory, contact your local Volvo dealer.

 

Further information

2
 

There may be parts in the accessories kit that are not needed for this installation.

 

Color symbols

3
IMG-363036
 

Note!
This colour chart displays (in colour print and electronic version) the importance of the different colours used in the images of the method steps.

  1. Used for focused component, the component with which you will do something.

  2. Used as extra colors when you need to show or differentiate additional parts.

  3. Used for attachments that are to be removed/installed. May be screws, clips, connectors, etc.

  4. Used when the component is not fully removed from the vehicle but only hung to the side.

  5. Used for standard tools and special tools.

  6. Used as background color for vehicle components.

 

Removal

4
IMG-430856
 

Open the hood.

5
IMG-400006
 

Drain the cooling system according to service information in VIDA:

Information / Repair / Cleaning, Inspection and Adjustment / 2 Engine with mountings and equipment / 26 Cooling system / 261 radiator and connections / Cooling system – draining, charging and bleeding.

6
IMG-403416
 

Note!
Orientation view

7
IMG-403425
 

Remove the marked detail/details.

Use: Pliers 31423632

8
IMG-426018
 

Remove the screws.

Remove the marked part.

9
IMG-430876
 

Remove the screws.

10
IMG-430810
 

Remove the screws.

Remove the clip.

11
IMG-430812
 

Remove the nuts.

 

Vehicles with air suspension

12
IMG-430818
 

Unhook the clip(s).

 

All vehicles

13
IMG-430845
 

Remove the marked part.

 

Accessory installation

14
IMG-430741
 

Locate relevant marking.

15
IMG-430742
 
16
IMG-430740
 

Use: Air-powered air saw

Adjust the hole with a file or knife as necessary.

17
IMG-436234
 

Install component that comes with the accessory kit.

Check that the flange of the part is in full contact with bumper cover.

Adjust the hole with a file or knife as necessary.

18
IMG-436235
 

Install components that come with the accessory kit.

19
IMG-430743
 

Note!
Note the position.

20
IMG-430771
 

Note!
Do not fully tighten the nut yet.

Install components that come with the accessory kit.

21
IMG-431625
 

This is used as a counterhold.

22
IMG-430775
 

Tighten the nut.

Use hands only.

23
IMG-430880
 

Note!
Orientation view

Ground connection

24
IMG-430905
 

Release the catches.

Fold marked part aside.

25
IMG-430885
 

Remove the nut.

The item is to be reused.

26
IMG-430888
 

Position/route the cable as illustrated.

27
IMG-430889
 

Connect the prerouted cable.

Install the nut.


Tightening torque: M6 , 10 Nm

28
IMG-430910
 

Reinstall the removed part.

29
IMG-430870
 

Position/route the cable as illustrated.

Install the cable.

Use a cable tie

30
IMG-431906
 

Caution!
No grease on contact surfaces.

Lubricate the O-ring.

31
IMG-431905
 
32
IMG-431910
 

Install the marked component.

Install the catch.

33
IMG-431915
 

Install components that come with the accessory kit.

  1. Passenger Compartment Connector Cable

  2. Cable from Engine block heater

34
IMG-430851
 
35
IMG-431645
 

Place the cable tie as illustrated.

36
IMG-431917
 

Tighten the cable tie.

37
IMG-431650
 

Note!
Orientation view

 

Vehicles with Power Pulse

38
IMG-431658
 

Note!
Orientation view

39
IMG-431657
 

Position/route the cable as illustrated.

Install the cable.

Use a cable tie

 

Applies to all other vehicles

40
IMG-431721
 

Note!
Orientation view

41
IMG-431720
 

Position/route the cable as illustrated.

Install the cable.

Use a cable tie

 

All vehicles

42
IMG-425906
 

Hold the component in the position in which it is to be fitted and mark the hoses where they are to be cut.

43
IMG-431707
 

Caution!
Cut carefully to avoid unintentional damage or personal injury.

44
IMG-430951
 

Assemble components that come with the accessory kit.

45
IMG-430946
 

Place the component where indicated in the graphic.

Tighten the screw.


Tightening torque: M6 , 10 Nm

46
IMG-431659
 

Remove the screw.

The item is to be reused.

47
IMG-391910
 
  1. Fold marked part aside.

  2. Install the marked components.

  3. Tighten the screw.

48
IMG-431670
 

Install components that come with the accessory kit.

Install the hoses.

Tighten the hose clamps.

49
IMG-431906
 

Caution!
No grease on contact surfaces.

Lubricate the O-ring.

50
IMG-431680
 

Connect the cable.

Install the catch.

51
IMG-394133
 

Position/route the cable as illustrated.

52
IMG-432235
 

Place the cable tie as illustrated.

Position/route the cable as illustrated.

Tighten the cable tie.

53
IMG-432236
 

Install the clip(s).

Position/route the cable as illustrated.

54
IMG-432237
 

Place the cable tie as illustrated.

Position/route the cable as illustrated.

Tighten the cable tie.

55
IMG-432238
 

Caution!
Install the cable tie only around steering gear and new wiring harness. The cable tie must not be installed around the existing wiring harness.

56
IMG-405608
 

Position/route the cable as illustrated.

Install the cable.

Use a cable tie

 

Removal

57
IMG-404385
 

Remove the clip.

58
IMG-404387
 

Fold the wing liner aside.

59
IMG-386950
 

Remove the nut.

Fold the insulation aside.

60
IMG-431925
 

Make a cut in the insulation.

61
IMG-386951
 

Remove the marked part.

The part is not to be reused.

62
IMG-432310
 
63
IMG-390109
 

Remove the panel.

Disconnect the connector, if applicable.

64
IMG-390116
 

Remove the panel.

65
IMG-390091
 

Disconnect the connector, if applicable.

66
IMG-390106
 

Remove the panel.

67
IMG-436220
 

Fold the carpet aside.

68
IMG-431961
 

Fold the insulation aside.

 

Accessory installation

69
IMG-431936
 
70
IMG-432240
 

Pull the wiring through.


Use special tool: T9814204, Expander pliers

71
IMG-394146
 

Caution!
Make sure that the rubber grommet seals properly to the body.

Insert the cable in to the passenger compartment, adjust the cable length out into the engine compartment and secure the rubber grommet.

72
IMG-432255
 

Position/route the cable as illustrated.

Install the cable.

Use a cable tie

73
IMG-431967
 

Refit the insulation.

Install the nut.

74
IMG-436233
 

Fold the carpet aside.

75
IMG-436216
 

Remove the screw.

The item is not to be reused.

Remove the marked part.

76
IMG-436242
 

Fold the floor carpet back.

77
IMG-405523
 

Take the template from the kit and cut it out following the dotted line.

78
IMG-432260
 

Mark using a pen

79
IMG-432261
 

Note!
Use a sharp knife.

80
IMG-432262
 

Remove the panel.

81
IMG-436232
 

Fold the carpet aside.

82
IMG-436212
 

Note!
Do not fully tighten the bolt.

Reinstall the removed part.

Install components that come with the accessory kit.

83
IMG-432201
 

Position/route the cable as illustrated.

84
IMG-431906
 

Caution!
No grease on contact surfaces.

Lubricate the O-ring.

85
IMG-432193
 

Install components that come with the accessory kit.

86
IMG-432195
 

Install components that come with the accessory kit.

87
IMG-431985
 

Fold the floor carpet back.

Adjust and center the passenger compartment power outlet in the hole of the carpet. The purpose is to have the outlet bezel cover the carpet edge.

Adjust the hole with a file or knife as necessary.

88
IMG-432229
 

Fold the carpet aside.

Remove the screws.

Fold marked part aside.

89
IMG-432227
 

Tighten the screw.


Tightening torque: M6 , 10 Nm

90
IMG-432230
 

Install the marked component.

Reinstall the screws.

91
IMG-432205
 

Make a cut in the insulation.

Remove the insulation material.

Fold the floor carpet back.

92
IMG-432191
 

Install component that comes with the accessory kit.

Note the position.

 

Installation

93
IMG-400006
 

Fill the cooling system according to the service information in VIDA:

Information / Repair / Cleaning, Inspection and Adjustment / 2 Engine with mountings and equipment / 26 Cooling system / 261 radiator and connections / Cooling system – draining, charging and bleeding.


Use special tool: T9512955, Cover

Use special tool: T9814192, Hose

Use special tool: T9512957, Coolant Reservoir

94
IMG-377070
 

Reinstall the removed parts in reverse order.

95
IMG-405228
 

Note!
Make sure to follow the sequence indicated.


Tightening torque: Aluminum wheel rim to wheel hub
Stage 1: 4 Nm
Stage 2: 50 Nm
Stage 3: 140 Nm