Installation Instruction

Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
S60 2021
S60 (19-) 2021 B4204T31, S60 (19-) 2021 B4204T20, S60 (19-) 2021 B4204T23, S60 (19-) 2021 B4204T26, S60 (19-) 2021 B4204T27, S60 (19-) 2021 B4204T29

Instruction NoVersionPart. No.Click to download PDF-version of this Installation Instruction
322893591.132147668
Electric engine heater and passenger compartment connector




IMG-464722




 

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-466541

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.

 

Color symbols

2
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

3
IMG-432310
 
4
IMG-426135
 

Set the vehicle to Inactive mode.

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-452753
 

Open the hood.

Raise the car.

20
IMG-452754
 

Note!
Orientation view

21
IMG-452756
 

Remove the marked detail/details.

Use: Pliers 31423632

Repeat on the other side.

22
IMG-452752
 

Remove the screws.

Remove the marked part.

Repeat on the other side.

23
IMG-454295
 

Remove the screws.

24
IMG-452766
 

Remove the clips.

Remove the nuts.

25
IMG-452767
 

Remove the screws.

Remove the clip.

26
IMG-452769
 

Remove the marked part.

27
IMG-452829
 

Remove the clips.

Remove the screws.

Remove the marked part.

28
IMG-454297
 

Remove the screws.

29
IMG-452853
 

Remove the clips.

30
IMG-452889
 

Remove the screws.

Loosen the component indicated. Do not remove it.

 

Applies to the left-hand side:

31
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

32
IMG-452966
 
  1. Remove the cable harness clips.

  2. Remove the hose.

33
IMG-452938
 

Remove the marked part.

 

Accessory installation

34
IMG-453341
 

Locate relevant marking.

35
IMG-453346
 
36
IMG-453347
 

Saw in a way so that the marking remains.

Use: Air-powered air saw

37
IMG-453354
 

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.

38
IMG-453355
 

Install component that comes with the accessory kit.

39
IMG-453356
 

Note!
Note the position.

40
IMG-453357
 

Note!
Do not fully tighten the nut yet.

Install components that come with the accessory kit.

41
IMG-453359
 

Install component that comes with the accessory kit.

This is used as a counterhold.

42
IMG-453358
 

Tighten the nut.

Use hands only.

43
IMG-453380
 

Note!
Orientation view

Ground connection

44
IMG-453385
 

Remove the nut.

The item is to be reused.

45
IMG-453393
 

Position/route the cable as illustrated.

46
IMG-453389
 

Connect the prerouted cable.

Install the nut.


Tightening torque: M6 , 10 Nm

47
IMG-453394
 

Position/route the cable as illustrated.

Install the cables.

Use a cable tie

48
IMG-441390
 

Caution!
No grease on contact surfaces.

Lubricate the O-ring.

49
IMG-440316
 
50
IMG-453615
 

Install the marked component.

Install the catch.

51
IMG-453863
 
  1. Passenger Compartment Connector Cable

  2. Engine heater cable

52
IMG-453617
 
  1. Passenger Compartment Connector Cable

  2. Engine heater cable

Install components that come with the accessory kit.

53
IMG-457995
 

Place the cable tie as illustrated.

54
IMG-457991
 

Position/route the cable as illustrated.

Tighten the cable tie.

55
IMG-453691
 

Note!
Orientation view

56
IMG-453890
 

Position/route the cables as illustrated.

assemble the cables.

Use a cable tie

57
IMG-453895
 

Place the cable tie as illustrated.

Position/route the cables as illustrated.

Tighten the cable tie.

58
IMG-453896
 

Install a clips onto the upper edge of the subframe.

Position/route the cables as illustrated.

Tighten the cable tie.

Install the cables.

59
IMG-462925
 

Place the cable tie as illustrated.

Position/route the cables as illustrated.

Tighten the cable tie.

60
IMG-462928
 

Position/route the cables as illustrated.

assemble the cables.

Use a cable tie

61
IMG-465304
 

Note!
Orientation view

  1. Passenger Compartment Connector Cable

  2. Engine heater cable

  3. Steering gear

  4. Cable harness

62
IMG-465995
 

Caution!
The cable ties must not be assembled around the steering gear wiring harness.


Note!
Fasten the cable ties without tightening.

Position/route the cables as illustrated.

Install the cables.

Use two assembled cable ties.

63
IMG-466492
 

Remove the screws.

64
IMG-464686
 

Clean the surface.

65
IMG-466482
 

Note!
Orientation view

66
IMG-466493
 

Install components that come with the accessory kit.

Tighten the screw.

67
IMG-465576
 

Remove the protective film.

68
IMG-466494
 

Install component that comes with the accessory kit.

69
IMG-466497
 

Press the marked component.

70
IMG-466498
 

Install components that come with the accessory kit.

Check that the bracket hole is centered against the screw head.

Tighten the screw.

71
IMG-441390
 

Caution!
No grease on contact surfaces.

Lubricate the O-ring.

72
IMG-464692
 

Connect the cable.

Install the catch.

73
IMG-465992
 

Fasten the cable tie without tightening.

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

Tighten the cable tie.

74
IMG-465993
 

Tighten the cable ties.

 

Removal

75
IMG-453668
 

Remove the clip.

Remove the screw.

76
IMG-453670
 

Remove the nuts.

77
IMG-453671
 

Fold the wing liner aside.

78
IMG-453672
 

Remove the marked part.

79
IMG-386950
 

Remove the nut.

Fold the insulation aside.

80
IMG-431925
 

Make a cut in the insulation.

81
IMG-386951
 

Remove the marked part.

 

Accessory installation

82
IMG-453673
 
83
IMG-453674
 

Pull the wiring through.


Use special tool: T9814204, Expander pliers

84
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.

85
IMG-453681
 

Refit the insulation.

Install the nut.

86
IMG-453678
 

Position/route the cable as illustrated.

Install the cable.

Use a cable tie

87
IMG-453582
 

Position/route the cable as illustrated.

88
IMG-453584
 

Note!
Do not fully tighten the bolt.

Reinstall the removed part.

Install components that come with the accessory kit.

89
IMG-441390
 

Caution!
No grease on contact surfaces.

Lubricate the O-ring.

90
IMG-453585
 

Install components that come with the accessory kit.

91
IMG-453586
 

Install components that come with the accessory kit.

92
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.

93
IMG-453593
 

Fold the carpet aside.

Remove the screws.

Fold marked part aside.

94
IMG-453600
 

Tighten the screw.


Tightening torque: M6 , 10 Nm

95
IMG-453594
 

Install the marked component.

Reinstall the screws.

96
IMG-432205
 

Make a cut in the insulation.

Remove the insulation material.

Fold the floor carpet back.

97
IMG-453596
 

Install component that comes with the accessory kit.

Note the position.

 

Installation

98
IMG-377070
 

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