Installation Instruction

Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
XC90 2012
XC90 (03-) 2012

Instruction NoVersionPart. No.Click to download PDF-version of this Installation Instruction
307563421.130756609, 30756339, 30756338, 30756337
Styling pack, skid plate and exhaust system




IMG-310308




 
Equipment
A0000162
IMG-239664
IMG-240693

IMG-310309

IMG-310311

IMG-310312

IMG-310313

IMG-213320


 
  

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.

  

Note!

On cars equipped with a towbar, installation kit, Towbar, installation kit, XC90 R-design containing two exhaust mountings must be obtained.


 
1
IMG-245980
 

  • Turn the ignition switch to position 0.


Note!

Wait at least three minutes before unplugging the connectors or removing other electrical equipment.


2
R8503999
 

Applies to cars with two rows of seats

  • Fold up the middle, rear floor hatch. Unhook the straps.

  • Detach the storage box underneath and lift it out.

  • Fold back the floor hatch. Pull the floor hatch backwards and lift it out.

Applies to cars with three rows of seats

  • Open the middle rear floor hatch.

  • Unhook the two cords at the front edge/underneath and lift out.

Applies to all models

  • Remove the tool box and equipment at the side of the battery.

3
R3100131
 

  • Remove the pre-punched pieces (1) from the insulation panel in the rear crossmember by cutting them off at the markings.

  • Remove the four sleeve nuts holding the bumper in place. They are in the holes under the insulation panel. Lift them out and remove them using a magnet

4
IMG-246058
 

Applies to cars with rear parking assistance

  • Remove the floor hatch (1) on the left-hand side.

5
IMG-246059
 

  • Remove the side panel on the left-hand side.

6A
IMG-310703
6B
IMG-310704
 

A and B

  • Detach the control module, it is secured by Velcro.

  • Remove the connector for the cable to the sensors.

7
IMG-310705
 

  • Press the foam rubber seal with cable into the hole in the bodywork.

8
IMG-310706
 

Applies to all models

  • Press in the middle pin on the clip in the lower mounting in the bumper panel and remove.

9
IMG-310707
 

  • Carefully pry the lower panel away from the bumper cover using a weatherstrip tool. Start at the lowermost edge. The skid plate is secured by surrounding catches.

  • Place to one side. A new panel is in the kit.

10
IMG-246027
 

Applies to cars with mudguards

  • Drill out the two rivets using a 6 mm (1/4") drill bit.

  • Leave the inner rivet in place.

  • Turn the mud guard outwards/downwards.

  • Repeat the operation on the other side.

11
IMG-311486
 

Applies to cars with body kit

Steps 11-17 are carried out on both sides


Note!

Wash and, if necessary, degrease the bumper and rear wings before removing the decor panels.


  • Mark the position of the decor panels against the bodywork using a whiteboard pen.

12
IMG-310885
 

  • Drill out the rivets in the rear wheel housings using a 6 mm (1/4") drill bit.

  • Remove any rivet remains from the wheel housings.

13
IMG-310884
 

  • Take a plastic weatherstrip and detach the decor panel. Start at the rear corner.


Caution!

Do not damage painted surfaces.



Hint

If the tape is securely attached, carefully heat the tape using a hot air gun to soften it up.


14
IMG-310883
 

  • Clean the bodywork from adhesive residue. Use tool 9512942 and 9512949. The clean using isopropanol.


Caution!

Do not use the tool on painted surfaces that have plastic carriers. On painted surfaces with plastic carriers the adhesive residue must be removed mechanically. Use a plastic weatherstrip and then clean using isopropanol.


15
IMG-310905
 

Preparing decor panel rear wing

  • Clean off any tape residue from the decor panel. Use a knife or putty knife.

  • Clean the area for the tape using isopropanol and wipe dry.

16
IMG-311504
 

  • Apply paint primer to the surfaces for the tape on the decor panel.


Caution!

Apply the tape after, the earliest 15 minutes, and at the latest 3 hours after applying the primer.


17
IMG-310963
 

  • Attach the tape to the decor panel as illustrated.

Installing the decor panel rear wing, as in last step.

For installation of decor panel rear wing, see:

  • VIDA

  • Installation instructions, accessories

  • 86, bumper, mudguards

  • 863 protectors and rubber protection

  • Body kit

  • Fastening side panel, rear fender

18
R8600883
 

Applies to all models

  • Drill out the rivets on the underneath of the front edge using a 6 mm (1/4") drill bit.

  • Repeat the operation on the other side.

19
R8600873
 

  • Remove the cover panel under the tail lamps on the right and left sides by carefully prying them loose using a weatherstrip tool.

20
IMG-246025
 

  • Disconnect the connector for the fog lamp on the left-hand side. The upper part of the connector must remain on its holder.

21A
IMG-246028
21B
IMG-246123
 

A and B

  • Pull off the lower section of the bumper cover at the front edge so that the two hooks at the upper edge, and the hooks on the inside, release.

  • Grasp the lower edge of the upper section of the bumper cover. Pull straight out so that the three hooks release. The hooks may be hard to release, if so, release using a weatherstrip tool.

  • Pull out the ends further until the four hooks, which are horizontally positioned at the upper edge, release.

  • Repeat the operation on the other side.

22
IMG-246029
 

  • Fold up the lower tailgate.

  • Pull the bumper backwards and remove.

  • Place the bumper on a suitable surface that will not damage the paint.

  • Remove the remaining parts of the removed rivets.

23
IMG-310983
 

Applies to cars with 8-cylinder engine

  • Remove the two nuts in the joint at the silencer.

  • Suspend the front section of the exhaust system to prevent damaging it at removal.


Note!

New clamp nuts and gasket must be used when installing the new exhaust system.


24
IMG-310984
 

Applies to cars with 6-cylinder engine

  • Remove the four nuts in the joint at the silencer.

  • Suspend the front section of the exhaust system to prevent damaging it at removal.


Note!

New clamp nuts and gasket must be used when installing the new exhaust system.


25
IMG-311023
 

Applies to cars with 8-cylinder and 6-cylinder engines

  • Remove the screws in the bracket under the exhaust pipe.

  • Remove the bracket with rubber mountings from the exhaust pipe. Use low temperature grease to get the rubber mountings to slide off the mounting hook more easily.

26
IMG-311043
 

Applies to cars with 5-cylinder diesel engine

  • Remove the two nuts in the joint at the silencer.

  • Suspend the front section of the exhaust system to prevent damaging it at removal.


Note!

New clamp nuts and gasket must be used when installing the new exhaust system.


27
IMG-311063
 

  • Remove the bolts in the bracket underneath the exhaust pipe and remove it.

28
IMG-311064
 

Applies to all models

  • Remove the rubber mountings from the mounting hooks in the bodywork. The rubber mountings will not be reused. New ones are in the kit.

29
IMG-311066
 

Applies to cars without a tow hitch


Note!

Two mechanics are needed for this step.


  • Remove the screws in the bracket underneath the left side member.

  • Pull out the exhaust pipe at the front joint and place to one side.

  • The rubber mounting with bracket will not be reused. New ones are in the kits. The screws will be reused.

  • Place the exhaust system to one side. New system in the kit.

  • Remove the gasket at the front joint and discard it. New nuts and new gasket will be used at installation.

30
IMG-311067
 

  • Remove the two screws in the bracket for the towing eyelet. The screws will be reused. Place the towing eyelet to one side. New one found in the kit.

31
IMG-311323
 

  • Take the left-hand mounting bracket from mounting kit exhaust system for cars without tow hitch and rubber mounting part no. 9186408 from installation kit exhaust system 8, 6 or 5 cyl diesel and install the rubber mounting on it.

  • Install the unit under the side member and install existing screws. Do not tighten hard yet.

32
IMG-311324
 

  • Take the new towing eyelet from installation kit exhaust system for cars without tow hitch and rubber mountingpart no. 9186408 frominstallation kit exhaust system 8, 6 or 5 cyl diesel and install the rubber mounting again on it.

  • Install the unit under the side member and install existing screws. Do not tighten hard yet.

33
IMG-311403
 

Applies to cars with a tow hitch


Note!

Two mechanics are needed for this step.


  • Unhook the silencer's rubber mounting from the hook on the tow bar's side panel.

  • Pull out the exhaust pipe at the front joint and place to one side.

  • The rubber mounting will not be reused. New mounting in the kit.

  • Place the exhaust system to one side. New system in the kit.

  • Remove the gasket at the front joint and discard it. New nuts and gasket will be used.

34
IMG-311423
 

  • Fold the silencer heat shield to one side to access the lower nuts for the tow bar's reinforcement plate.

  • Remove the nuts and discard them. Turn the screws and reinstall.

  • Repeat the operation on the other side.

35
IMG-302184
 

  • Take the mounting hooks from the kitTowbar, installation kit, XC90 R-design and install the hook on the screws. Take new nuts, install them and tighten to 50 Nm (37 lbf.ft.).

  • Repeat the operation on the other side.

36
IMG-311424
 

  • Install new rubber mounting part no. 9186408 from installation kit exhaust system 8, 6 or 5 cyl diesel on the hook.

  • Repeat the operation on the other side.

37
IMG-311425
 

Applies to cars with parking assistance

  • Disconnect the cable harness to the sensors from the rear section of the bumper.

38
IMG-311505
 

Applies to all models

  • Unhook the ten catches at the upper edge of the bumper.

  • Release the nine hooks in the middle of the bumper, at the same time as separating the rear section and outer section of the bumper.

  • Remove the rear section from the bumper cover.

39A
IMG-311444
39B
IMG-311445
39C
IMG-311446
 

Applies to cars with a tow hitch

  • Take a new holder for the bumper from the kit and saw out according to the marking. Remove the shaded area.

  • Smooth off the sawn edges with a fine toothed file.

  • A Detachable towbar

  • B Fixed towbar

  • C Hitch towbar

40
IMG-315623
 

  • Take the bumper's rear section and measure the dimension as illustrated. Carefully saw off the holder on the rear section. It will not be reused.

  • Smooth off the edges using a file.

41
IMG-315624
 

  • Smooth off the edges on the inside where the new holder is to be placed against.

42
IMG-315625
 

  • Take the holder from the kit and secure the rear section from the inside.

43A
IMG-315626
43B
IMG-315627
 

A

  • Take measurements for the drilling of the three holes for the attachment of the holder.

  • Secure the holder to the rear section properly and drill out the three holes through the rear section and holder.

  • Remove any swarf.

B

  • Image B shows dimension drawing of the location of the holes.

  • Same hole position in all locations.

44
IMG-315628
 

  • Take rivets from the kit and rivet the rear section into place.

45
IMG-311506
 

  • Secure the rear section in the bumper cover. Make sure that all catches engage.

Applies to cars with parking assistance

  • Ensure that the wiring for the sensors is correctly positioned.

46
IMG-311450
 

Applies to cars with parking assistance

  • Secure the cable harness for the sensors in the rear section.

47
IMG-311463
 

Applies to all models

  • Take the two rubber mountings part no. 9179238 from kit exhaust system 8 or 6 cyl, or part no. 9492157 from exhaust system 5 cyl diesel.

  • Install them in the suspension hooks in the bodywork.

48
IMG-311483
 


Note!

Two mechanics are needed for this step.

Ensure that the mating surfaces in the joint between the various parts in the exhaust system are clean.

All clamp nuts and gaskets must be replaced with new ones.


  • Take the long part of the new exhaust system and install.

49
IMG-311484
 

  • Hook the rubber mounting onto the exhaust system brackets.

50
IMG-310983
 

Applies to cars with 8-cylinder engine

  • Tighten the nuts to 25 Nm (18.5 lbf.ft).

51
IMG-310984
 

Applies to cars with 6-cylinder engine

  • Tighten the nuts to 25 Nm (18.5 lbf.ft).

52
IMG-311023
 

Applies to cars with 6 and 8 cylinder engines

  • Torque tighten the screws to 25 Nm (18.5 lbf.ft.).

53
IMG-311043
 

Applies to cars with 5-cylinder diesel engine

  • Tighten the nuts to 25 Nm (18.5 lbf.ft).

54
IMG-311063
 

  • Torque tighten the screws to 25 Nm (18.5 lbf.ft.).

55
IMG-311524
 

Applies to all models

  • Hook the rubber mounting on for the left silencer.

56
IMG-311525
 

  • Take the remaining silencer from the kit and install it on the previously installed exhaust system.

  • Hook the previously installed rubber mounting onto the silencer's hook.

  • Do not tighten the joint in the silencer yet.

57A
IMG-311545
57B
IMG-311547
57C
IMG-311548
 

A, B, and C

  • Reinstall the bumper cover.

  • Connect the connector under the rear lamp.

Applies to cars with parking assistance

  • Position the connector for the sensors on the lug on the rear section.

58
IMG-311550
 

Applies to cars with mudguards

59
IMG-311551
 

Applies to all models

60
IMG-311552
 

61
IMG-311553
 

  • Install the four nuts that hold the bumper to the bodywork. Tighten to 24 Nm (18 lbf.ft.).

  • Reinstall the four pieces of insulation.

62
R3904120
 

Applies to cars with parking assistance

  • Route the connector for the cable to the sensors.

  • Secure the foam rubber seal.

63A
IMG-311554
63B
IMG-311555
 

64
IMG-311567
 

65
IMG-311556
 

66
IMG-311557
 

67A
IMG-302343
67B
IMG-302344
67C
IMG-302243
 

Applies to cars with a tow hitch

  • Take the skid plate from the kit and saw out according to the markings. Remove the shaded area.


Note!

Do not damage the paintwork of the bumper cover.


  • Smooth off the sawn edges with a fine toothed file.

  • A Detachable towbar

  • B Fixed towbar

  • C Hitch towbar

68A
IMG-302283
68B
IMG-311563
 

Applies to all models

A and B

  • Secure the skid plate in the bumper cover. Make sure that all catches engage.

  • Take four clips from the kit. Fold up the rear edge on the skid plate around the holder and install with the clips.

69
IMG-311564
 

  • Secure the cord for the cover to the towing eyelet mounting in the lower right-hand corner of the hole in the skid plate. Secure the cover in the skid plate.

70A
IMG-311565
70B
IMG-311566
 

A

  • Align the silencer's end pipes in the cut-out in the skid plate so that they are centered in the cut-out on both sides.

Applies to cars without a tow hitch

  • Tighten the screws in the brackets for the mountings for the rear silencers. Torque tighten to 80 Nm (59 lbf.ft.).

B

  • Tighten the nut at the joint for the right-hand silencer. Torque tighten to 37 Nm (50 lbf.ft.).