Installation Instruction

Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
V60 Cross Country 2019
V60 Cross Country (19-) 2019 D4204T14, V60 Cross Country (19-) 2019 D4204T4

Instruction NoVersionPart. No.Click to download PDF-version of this Installation Instruction
322700961.031454669
Electric engine heater and passenger compartment connector




IMG-454329




 

Special tools

 

999 7669 Key

Tool number:999 7669

Tool description:Key

Tool boards:20

 

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-453786

IMG-453787


 
 

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-400010
 

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.

  7. Used for accessory components.

 

Removal

4
IMG-432310
 
5
IMG-436053
 

Remove the panel.

Disconnect the connector, if applicable.

6
IMG-436055
 

Remove the panel.

7
IMG-450389
 

Remove the panel.

8
IMG-450410
 

Remove the panel.

9
IMG-436233
 

Fold the carpet aside.

10
IMG-436216
 

Remove the screw.

The item is not to be reused.

Remove the marked part.

11
IMG-436242
 

Fold the floor carpet back.

12
IMG-453575
 

Reinstall the removed part.

13
IMG-405523
 

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

14
IMG-453578
 

Mark using a pen

15
IMG-453579
 

Note!
Use a sharp knife.

16
IMG-450410
 

Remove the panel.

17
IMG-436220
 

Fold the carpet aside.

18
IMG-453580
 

Fold the insulation aside.

19
IMG-456269
 

Note!
Orientation view

20
IMG-452756
 

Remove the marked detail/details.

Use: Pliers 31423632

Repeat on the other side.

21
IMG-456271
 

Remove the screws.

Remove the marked part.

Repeat on the other side.

22
IMG-456273
 

Remove the screws.

23
IMG-452766
 

Remove the nuts.

Remove the clips.

24
IMG-456275
 

Remove the screws.

25
IMG-456276
 

Remove the clip.

26
IMG-456277
 

Remove the marked part.

27
IMG-456266
 

Open the hood.

Raise the car.

28
IMG-452829
 

Remove the clips.

Remove the screws.

Remove the marked part.

29
IMG-456279
 

Remove the screws.

30
IMG-456320
 

Remove the clips.

31
IMG-456321
 

Remove the screws.

Loosen the component indicated. Do not remove it.

 

Applies to the left-hand side:

32
IMG-452964
 
  1. Remove the connector from its attachment.

  2. Remove the cable harness clips.

  3. Remove the hose.

 

Applies to the right-hand side

33
IMG-452966
 
  1. Remove the cable harness clips.

  2. Remove the hose.

34
IMG-456324
 

Remove the marked part.

35
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.


Use special tool: T9997669, Key

 

Accessory installation

36
IMG-456285
 

Locate relevant marking.

37
IMG-456289
 
38
IMG-456290
 

Saw in a way so that the marking remains.

Use: Air-powered air saw

39
IMG-456296
 

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.

40
IMG-456298
 

Install components that come with the accessory kit.

41
IMG-456303
 

Note!
Note the position.

42
IMG-456306
 

Note!
Do not fully tighten the nut yet.

Install components that come with the accessory kit.

43
IMG-456304
 

Install component that comes with the accessory kit.

This is used as a counterhold.

44
IMG-456307
 

Tighten the nut.

Use hands only.

45
IMG-456354
 

Note!
Orientation view

Ground connection

46
IMG-453385
 

Remove the nut.

The item is to be reused.

47
IMG-453393
 

Position/route the cable as illustrated.

48
IMG-453389
 

Connect the prerouted cable.

Install the nut.


Tightening torque: M6 , 10 Nm

49
IMG-456357
 

Position/route the cables as illustrated.

Install the cables.

Use a cable tie

50
IMG-441390
 

Caution!
No grease on contact surfaces.

Lubricate the O-ring.

51
IMG-440316
 
52
IMG-453615
 

Install the marked component.

Install the catch.

53
IMG-453616
 
  1. Passenger Compartment Connector Cable

  2. Cable from Engine block heater

54
IMG-453617
 

Install components that come with the accessory kit.

  1. Passenger Compartment Connector Cable

  2. Cable from Engine block heater

55
IMG-453402
 
56
IMG-456435
 

Place the cable tie as illustrated.

57
IMG-457991
 

Tighten the cable tie.

58
IMG-456360
 

Note!
Orientation view

59
IMG-453454
 

Position/route the cable as illustrated.

60
IMG-453456
 

Install the cable.

Use a cable tie

61
IMG-453458
 

Note!
Orientation view

62
IMG-453297
 

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

63
IMG-431707
 

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

64
IMG-452743
 

Note!
Do not fully tighten the bolt.

Assemble components that come with the accessory kit.

65
IMG-453318
 

Adjust the position of the component according to image.

Tighten the screw.


Tightening torque: M6 , 10 Nm

66
IMG-431659
 

Remove the screw.

The item is to be reused.

67
IMG-453321
 
  1. Fold marked part aside.

  2. Install the marked components.

  3. Reinstall the screw.

68
IMG-453326
 

Attach the hose clamp

Install the hoses.

Tighten the hose clamps.

69
IMG-441390
 

Caution!
No grease on contact surfaces.

Lubricate the O-ring.

70
IMG-453330
 

Connect the cable.

Install the catch.

71
IMG-453629
 

Note!
Orientation view

Passenger Compartment Connector Cable

72
IMG-453632
 

Position/route the cable as illustrated.

73
IMG-453643
 

Place the cable tie as illustrated.

Position/route the cable as illustrated.

Tighten the cable tie.

74
IMG-453697
 

Fasten the clamp.

Position/route the cable as illustrated.

75
IMG-453646
 

Place the cable tie as illustrated.

Position/route the cable as illustrated.

Tighten the cable tie.

76
IMG-453656
 

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.

77
IMG-453659
 

Position/route the cable as illustrated.

Install the cable.

Use a cable tie

 

Removal

78
IMG-457992
 

Remove the clip.

Remove the screw.

79
IMG-453670
 

Remove the nuts.

80
IMG-458091
 

Fold the wing liner aside.

81
IMG-453672
 

Remove the marked part.

82
IMG-386950
 

Remove the nut.

Fold the insulation aside.

83
IMG-431925
 

Make a cut in the insulation.

84
IMG-386951
 

Remove the marked part.

The part is not to be reused.

 

Accessory installation

85
IMG-453673
 
86
IMG-453674
 

Pull the wiring through.


Use special tool: T9814204, Expander pliers

87
IMG-453677
 

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.

88
IMG-453681
 

Refit the insulation.

Install the nut.

89
IMG-453678
 

Position/route the cable as illustrated.

Install the cable.

Use a cable tie

90
IMG-453582
 

Position/route the cable as illustrated.

91
IMG-453584
 

Note!
Do not fully tighten the bolt.

Reinstall the removed part.

Install components that come with the accessory kit.

92
IMG-441390
 

Caution!
No grease on contact surfaces.

Lubricate the O-ring.

93
IMG-453585
 

Install components that come with the accessory kit.

94
IMG-453586
 

Install components that come with the accessory kit.

95
IMG-453591
 

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.

96
IMG-453593
 

Fold the carpet aside.

Remove the screws.

Fold marked part aside.

97
IMG-453600
 

Tighten the screw.


Tightening torque: M6 , 10 Nm

98
IMG-453594
 

Install the marked component.

Reinstall the screws.

99
IMG-432205
 

Make a cut in the insulation.

Remove the insulation material.

Fold the floor carpet back.

100
IMG-453596
 

Install component that comes with the accessory kit.

Note the position.

 

Installation

101
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

102
IMG-377070
 

Reinstall the removed parts in reverse order.

103
IMG-456337
 

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