Installation Instruction

Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
XC40 2019
B4204T14, B4204T18, B4204T20, B4204T36, B4204T47

Instruction NoVersionPart. No.Click to download PDF-version of this Installation Instruction
322893631.032147660
Electric engine heater and passenger compartment connector




IMG-467023




 

Special tools

 

981 4204 Expander pliers

Tool number:981 4204

Tool description:Expander pliers

Tool boards:87


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

IMG-466925

IMG-467024


 
 

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-440436
 

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-442590
 
5
IMG-430215
 

Set the vehicle to Inactive mode.

6
IMG-431485
 

Remove the panel.

Disconnect the connector, if applicable.

7
IMG-431600
 

Remove the panel.

8
IMG-431605
 

Remove the panel.

9
IMG-443405
 

Remove the screws.


Tightening torque: Front seat to body , 40 Nm

10
IMG-442591
 
11
IMG-443407
 

Remove the screws.


Tightening torque: Front seat to body , 40 Nm

12
IMG-445881
 

Remove the screws.

Remove the nut.

Fold marked part aside.

13
IMG-431651
 

Remove the marked part.

14
IMG-431640
 

Remove the clip.

15
IMG-431652
 

Remove the marked part.

 

Accessory installation

16
IMG-444102
 

Screw and unscrew to ease assembly later.

17
IMG-440386
 

Place the component where indicated in the graphic.

Make a hole, using the tool indicated.

18
IMG-440394
 

Install components that come with the accessory kit.

19
IMG-440395
 

Install components that come with the accessory kit.

Remove the protective film.

20
IMG-440401
 

Note!
Press and apply pressure to the part over the tape for at least 20 seconds.

Install the marked components.

 

Removal

21
IMG-439740
 

Open the hood.

22
IMG-403425
 

Remove the marked detail/details.

Use: Pliers 31423632

Repeat on the other side.

23
IMG-467146
 

Remove the screws.

Remove the marked part.

Repeat on the other side.

24
IMG-438237
 

Remove the screws.

Remove the marked part.

25
IMG-439752
 

Remove the clips.

Remove the nuts.

26
IMG-439754
 

Remove the screws.

Remove the clip.

27
IMG-439755
 

Remove the marked part.

 

Accessory installation

28
IMG-439819
 
29
IMG-440215
 

Secure the template with tape.

30
IMG-440216
 

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

Cut out following the template.

Make a mark by cutting a thin cut.

Remove template.

31
IMG-440041
 
  1. Use a drill with the stated size

  2. Use: Air-powered air saw

32
IMG-440192
 

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.

33
IMG-440181
 

Install component that comes with the accessory kit.

34
IMG-440194
 

Note!
Note the position.

35
IMG-440190
 

Note!
Do not fully tighten the nut yet.

Install components that come with the accessory kit.

36
IMG-440208
 

Install component that comes with the accessory kit.

This is used as a counterhold.

37
IMG-440209
 

Tighten the nut.

Use hands only.

38
IMG-440605
 

Note!
Orientation view

Ground connection

39
IMG-440607
 

Release the catches.

Fold marked part aside.

40
IMG-440610
 

Remove the nut.

The item is to be reused.

41
IMG-467022
 

Connect the prerouted cable.

42
IMG-467020
 

Reinstall the removed part.

43
IMG-467019
 

Install the nut.


Tightening torque: M6 , 10 Nm

44
IMG-440316
 

Caution!
No grease on contact surfaces.

Cable from front socket

Lubricate the O-ring.

45
IMG-451566
 

Use details according to image.

  1. Passenger Compartment Connector Cable

  2. Engine heater cable

46
IMG-440990
 
  1. Passenger Compartment Connector Cable

  2. Engine heater cable

Assemble components that come with the accessory kit.

47
IMG-440995
 

Place the cable tie as illustrated.

48
IMG-442605
 

Position/route the cables as illustrated.

49
IMG-442606
 

Position/route the cables as illustrated.

50
IMG-441390
 

Caution!
No grease on contact surfaces.

Cable from front socket

Lubricate the O-ring.

51
IMG-442607
 

Connect the cable.

52
IMG-442608
 
53
IMG-442609
 
54
IMG-442610
 

Note!
Image shows vehicle without battery.

Attach the clip.

55
IMG-467036
 

Note!
Orientation view

  1. Passenger Compartment Connector Cable

  2. Engine heater cable

56
IMG-451694
 

Place the cable tie as illustrated.

Position/route the cables as illustrated.

Tighten the cable tie.

57
IMG-451700
 

Place the cable tie as illustrated.

Position/route the cables as illustrated.

Tighten the cable ties.

58
IMG-451706
 

Place the cable tie as illustrated.

Position/route the cables as illustrated.

Tighten the cable tie.

59
IMG-466939
 

Place the cable tie as illustrated.

Position/route the cables as illustrated.

Tighten the cable tie.

60
IMG-452650
 

Note!
Orientation view

61
IMG-452651
 

Loosen the hose clamp.

Undo the hose from the connection.

Release the lock.

Remove the marked part.

62
IMG-467048
 

Note!
Orientation view

  1. Steering gear

  2. Engine heater cable

  3. Passenger Compartment Connector Cable

63
IMG-467062
 

Position/route the cables as illustrated.

Install the cables.

Use a cable tie

64
IMG-467063
 
  1. Passenger Compartment Connector Cable

  2. Engine heater cable

Position/route the cables as illustrated.

Install the cable.

65
IMG-441390
 

Caution!
No grease on contact surfaces.

Lubricate the O-ring.

66
IMG-440901
 

Use detail according to image.

67
IMG-452687
 

Connect the cable.

Install the catch.

68
IMG-452686
 

Place the cable tie as illustrated.

Position/route the cables as illustrated.

Tighten the cable ties.

69
IMG-440935
 

Remove the nuts.

70
IMG-440939
 

Fold the insulation aside.

71
IMG-440940
 

Make a cut in the insulation.

72
IMG-440955
 

Remove the marked part.

The part is not to be reused.

73
IMG-440965
 

Push the tool through the insulation into the compartment.

Use: Scribe

Allow the tool to remain.

74
IMG-441376
 

Make a cut in the insulation.

75
IMG-441380
 

Fold the insulation aside.

Remove the tool.

76
IMG-440946
 
77
IMG-441082
 

Pull the wiring through.


Use special tool: T9814204, Expander pliers

78
IMG-441083
 

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.

79
IMG-441089
 

Refit the insulation.

Install the nuts

80
IMG-467183
 

Remove the screws.

81
IMG-467184
 

Clean the surface.

82
IMG-466482
 

Note!
Orientation view

83
IMG-466493
 

Install components that come with the accessory kit.

Tighten the screw.

84
IMG-465576
 

Remove the protective film.

85
IMG-467185
 

Install component that comes with the accessory kit.

86
IMG-467186
 

Press the marked component.

87
IMG-467187
 

Install components that come with the accessory kit.

Tighten the screw.

88
IMG-467065
 

Secure the cable with clips in the subframe flange.

89
IMG-441390
 

Caution!
No grease on contact surfaces.

Lubricate the O-ring.

90
IMG-467194
 

Connect the prerouted cable.

Install the catch.

91
IMG-467188
 

Reinstall the removed part.

92
IMG-466959
 

Fasten the cable tie without tightening.

Adjust the cable position so that it can follow the motions of the engine.

Tighten the cable tie.

93
IMG-442618
 

Install the marked component.

94
IMG-442626
 

Take a scriber and make a hole in the carpet opposite the two holes in the bracket.

95
IMG-441390
 

Caution!
No grease on contact surfaces.

Lubricate the O-ring.

96
IMG-444091
 

Install components that come with the accessory kit.

97
IMG-442627
 

Install the screws.

 

Installation

98
IMG-400000
 

Reinstall the removed parts in reverse order.

99
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