Installation Instruction

Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
V60 Cross Country 2018
V60 Cross Country (-18) 2018 D5244T21

Instruction NoVersionPart. No.Click to download PDF-version of this Installation Instruction
313594571.031359437
Electric engine heater, passenger compartment connector, 4-cyl/5-cyl




IMG-265587




 
Equipment
A0000162
IMG-239664
IMG-239980

IMG-359956

IMG-359957


 
  

INTRODUCTION

  • 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.

 
1
IMG-217765
 

Applies to all models

  • Remove the tunnel console's right-hand side panel by carefully pulling it away starting at the front edge. The side panel is secured with five clips on the inside.

2
IMG-217766
 

  • Uncover the right-hand side of the tunnel console's front section and the hole for the rubber grommet to the engine compartment by folding aside the passenger compartment carpet and the insulation panel underneath this.

3
IMG-217767
 

  • Undo the front screw in the mounting for the centre console.

  • Take the bracket for the passenger compartment connector from the kit and tighten it in with the previously removed screw.

  • Align the bracket so that it is straight and torque tighten the screw to 24 Nm (18 lbf.ft.).

4
IMG-217768
 

  • Fold the carpet back toward the bracket.

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

5
IMG-217769
 

  • Take the passenger compartment connector socket and two screws from the kit and tighten the passenger compartment connector socket into the bracket.

6
IMG-217770
 

  • Press a locking sleeve (from the kit) onto the passenger compartment connector socket. Slide the locking sleeve as far along the terminal for the passenger compartment connector socket as possible.

  • Take a carpet knife and cut a slit in the carpet just in front of the locking sleeve. Make the cut as long as the diameter of the locking sleeve.


Note!

Do not damage any wiring and hoses under the carpet.


  • Remove the passenger compartment connector socket from the bracket and fold the carpet to one side.

7
IMG-341077
 

8
IMG-341082
 

9
IMG-341081
 

10
IMG-340576
 

11
IMG-231821
 

  • Remove the rubber seal in the cowl panel. It shall not be used again.

12
IMG-318204
 

Applies to cars with 5-cyl. diesel and twin turbos

  • Fold and secure the edge of the wheel housing's inner wing to one side on the right-hand side to facilitate access when installing and when cable routing in the cowl panel.

13
IMG-318206
 

  • Remove the strut under the catalytic converter.

14
IMG-318207
 

  • Remove the screws from the catalytic converter bracket.

15
IMG-318208
 

  • Carefully move the catalytic converter to the left side towards the stop.

  • Secure the catalytic converter with cable ties in the hole for the screw to the removed strut and the stay on the catalytic converter.

16
IMG-231822
 

Applies to 5-cyl with installed electric engine heater

  • Cut off the tie strap that holds the cable splice in the front edge of the subframe.

  • Detach the cable from the two clips in the subframe.

17
IMG-231823
 

  • Remove the locking sleeve and pull the joint apart.

18
IMG-231826
 

Applies to 5-cyl

  • Take a new tie strap equipped with clip from the kit and install it in the subframe.

19
D3601932
 

  • Grease in the O-ring on the connector to the front socket, both connectors on the junction connector and the O-ring on the passenger compartment connector's joint cable, using low temperature grease P/N 1161427.


Note!

Do not get any grease on the surfaces of the connector.


20
IMG-231829
 

  • Press the cables firmly into the junction connector in accordance with the following:

    Cable (1) to the front socket.

    Cable (2) to the passenger compartment connector socket.

    Cable (3) to the heater.

  • Take three locking sleeves from the kit and install them over the joints.

21A
IMG-231830
21B
IMG-318243
 

Illustration A

Applies to 5-cyl

  • Press the cables for the heater and front socket into their clips.

  • Tighten the junction connector into the subframe using the tie strap in the rear hole in the junction connector.

Illustration B

Applies to 5-cyl and twin turbo

  • Use the entire length of the cable from the front socket and route the junction connector as far to the right as possible. If necessary, move the clips on the sub frame's upper edge to the right.

  • Insert the junction connector in the space in the sub-frame and tighten down the junction connector around the rear cable with a cable tie in the hole at the top of the sub-frame.

22A
IMG-231831
22B
IMG-231832
 

Applies to 5-cyl

Illustration A

  • Route the cable for the passenger compartment connector the same way as the cable for the heater up to the steering gear.

  • Take three tie straps from the kit and clamp the cable into the heater cable.

  • Position the cable (1) for the passenger compartment connector inside the bracket (2) in the front edge of the subframe's front right-hand corner (Illustration B).

Illustration B

23
IMG-342533
 

  • Continue to route the cable around the right-hand front corner of the subframe and clamp it into the existing cable using a tie strap from the kit.

24A
IMG-342108
24B
IMG-342107
 

Illustration A

  • Route the cable further along the cable to the electric engine heater up towards the power steering servo.

  • Clamp using cable ties.


Note!

Make sure that the cable is routed so that it does not make contact with the pulley or the belt for the air conditioning compressor.


Illustration B

25A
IMG-359905
25B
IMG-359906
 

Illustration A


Note!

Do not clamp the cable so that it is in direct contact with brake pipes, fuel lines, AC pipes or pipes to the power steering.


Illustration B

26
IMG-231839
 

  • Take the rubber grommet and cut away the very top of the largest rubber teat.

27
IMG-359911
 

  • Take the radiation shield from the kit and thread it on the cable to the passenger compartment connector socket. Pull the radiation shield up to the cable clamp.

  • Adjust the length of the radiation protection up to the hole for the rubber grommet and cut off the excess.

28
IMG-342587
 

  • Grease in the rubber grommet using low temperature grease P/N 1161427 in order to make it easier to insert the cable and rubber grommet into the hole in the cowl panel.


Note!

Do not get any grease on the surfaces of the connector.


  • Thread the rubber grommet onto the cable.

  • Adjust the length of the cable from the rubber grommet and out into the engine compartment so that it runs true and does not come into contact with moving parts in the engine compartment. Conceal all cable excess under the mat in the passenger compartment.

29
IMG-342580
 

  • Insert the cable into the passenger compartment.

  • Press the rubber grommet into the cowl panel.

  • Take the grey tie strap from the kit and tighten the radiation shield upper end into the cable.

30
IMG-318264
 

Applies to 5-cyl with twin turbo

31
IMG-318266
 

32
IMG-318267
 

33
IMG-318268
 

34
IMG-341108
 

Applies to 4-cyl and heater installed

  • Disconnect the cable from the clips.

35
IMG-231823
 

  • Remove the locking sleeve and pull the joint apart.

36
IMG-231826
 

Applies to 4-cyl

  • Take a new tie strap equipped with clip from the kit and install it in the subframe.

37
D3601932
 

  • Grease in the O-ring on the connector to the front socket, both connectors on the junction connector and the O-ring on the passenger compartment connector's joint cable, using low temperature grease P/N 1161427.


Note!

Do not get any grease on the surfaces of the connector.


38
IMG-231829
 

  • Secure the cables firmly in the junction connector as follows: Cable (1) to the front intake. Cable (2) to the passenger compartment connector. Cable (3) to the heater.

  • Take three locking sleeves from the kit and install them over the joints.

39
IMG-341086
 

  • Press the cables for the heater and front socket into their clips.

  • Tighten the junction connector into the subframe using the tie strap in the rear hole in the junction connector.

40
IMG-330311
 

  • Press two clips from the kit into place on the sub-frame's upper edge.

41
IMG-330317
 

  • Press the cable for the passenger compartment connector socket into both clips.

42
IMG-342595
 

  • Take a cable tie with edge clip from the kit and secure the sub-frame's right-hand front corner.

43A
IMG-332957
43B
IMG-332958
 

Applies to cars without electric power steering pump

Illustration A


Note!

The holes in the right-hand side of the sub-frame, which are used for securing the passenger compartment connector cable, have rivet nuts. In order for the clips in the kit to fit, these must be cut off.


  • Cut the clip on two sides as shown in figure A and B.

Illustration B

44
IMG-332959
 

  • Screw the clips into the rivet nuts.

45A
IMG-359905
45B
IMG-359906
 

Applies to all models

Illustration A

Illustration B

46A
IMG-342603
46B
IMG-277511
 

Illustrations A and B

    Illustration A

  • Pull up the cable in front of the sub-frame's right front corner. Position it as shown and tighten the cable tie.


Note!

Do not clamp the cable directly to brake pipes, fuel lines, power steering pipes or AC pipes.


Applies to cars without electric power steering pump

    Illustration B

  • Continue routing the cable towards the inside of the subframe and clamp it using the two cable ties.

47
IMG-359936
 

Secure the cable harness with the clips.

48
IMG-231839
 

  • Take the rubber grommet from the kit and cut away the very top of the largest rubber teat.

49
IMG-277513
 

  • Adjust the length of the cable from place where the rubber grommet should be located and out into the engine compartment so that it runs true and does not come into contact with any moving parts in the engine compartment. Conceal all cable excess under the mat in the passenger compartment.

  • The radiation shield may need to be cut to fit the length of the cable between the clamp and the rubber lead-in in the firewall.

  • Take the radiation shield from the kit and thread it on the cable to the passenger compartment connector socket. Pull the radiation shield up to the clamp.

50
IMG-277514
 

  • Grease the rubber grommet using low temperature grease in order to make it easier to insert the cable and rubber grommet into the hole in the cowl panel.


Note!

Do not get any grease on the surfaces of the connector.


  • Thread the rubber grommet onto the cable.

51
IMG-277515
 

  • Insert the cable into the passenger compartment.

  • Press the rubber grommet into the cowl panel.

52
IMG-277516
 

  • Take the grey tie strap from the kit and tighten the radiation shield upper end into the cable.

53
IMG-340577
 

Applies to 4 and 5-cyl

54
IMG-341107
 

55
IMG-341082
 

56
IMG-341106
 

57A
IMG-217776
57B
IMG-217777
 

    Illustration A

  • Route the cable onto the bracket for the passenger compartment connector socket.

    Illustration B

  • Route the cable from the engine compartment through the hole in the carpet.

  • Lubricate the O-ring using low temperature grease.


Note!

Ensure that no grease gets onto the connector surfaces.


  • Connect the cable to the passenger compartment connector socket. Press a locking sleeve (from the kit) over the joint.

  • Fold the carpet back into position and install the passenger compartment connector socket using both the screws.

58
IMG-234260