Installation Instruction

Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
V90 Cross Country 2020
B4204T20, B4204T23, B4204T26, B4204T27, B4204T29

Instruction NoVersionPart. No.Click to download PDF-version of this Installation Instruction
322411191.132147664
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


Materials

Designation

Part number

Low temperature grease

1161427


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

IMG-466726

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-414525
 
4
IMG-426135
 

Set the vehicle to Inactive mode.

5
IMG-412242
 

Remove the panel.

Disconnect the connector, if applicable.

6
IMG-414575
 

Remove the panel.

7
IMG-414580
 

Remove the panel.

Disconnect the connector, if applicable.

8
IMG-455950
 

Remove the panel.

9
IMG-456003
 

Fold the carpet aside.

10
IMG-436216
 

Remove the screw.

The item is not to be reused.

Remove the marked part.

11
IMG-466688
 

Fold the floor carpet back.

12
IMG-466689
 

Reinstall the removed part.

13
IMG-405523
 

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

14
IMG-466692
 

Mark using a pen

15
IMG-466691
 

Note!
Use a sharp knife.

16
IMG-455950
 

Remove the panel.

17
IMG-455984
 
18
IMG-421025
 

Fold the insulation aside.

19
IMG-466725
 

Open the hood.

20
IMG-466723
 

Note!
Orientation view

21
IMG-452756
 

Remove the marked detail/details.

Use: Pliers 31423632

Repeat on the other side.

22
IMG-466730
 

Remove the screws.

Remove the marked part.

Repeat on the other side.

23
IMG-466737
 

Remove the clips.

Remove the screws.

24
IMG-448299
 

Remove the nut.

25
IMG-466736
 

Remove the screws.

26
IMG-421165
 

Remove the nut.

Remove the clip.

27
IMG-466734
 

Remove the marked part.

28
IMG-466760
 
29
IMG-466768
 
30
IMG-448503
 

Remove the cable harness clips.

31
IMG-448504
 

Loosen the screws.

Remove the marked part.

32
IMG-448505
 

Caution!
Take extra care when handling the component.

Fold marked part aside.

33
IMG-448506
 

Remove the screws.

Remove the marked part.

34
IMG-428776
 

Note!
Orientation view

35
IMG-428775
 

Remove the screw.

Release the catches.

Remove the marked part.

 

Accessory installation

36
IMG-450076
 

Note!
Orientation view

37
IMG-450093
 

Measure and mark out the centre.

Use a drill with the stated size

38
IMG-448275
 

Assemble components that come with the accessory kit.

39
IMG-450095
 

Pull the wiring through.

40
IMG-466785
 

Note!
Note the position.

41
IMG-450185
 

Install component that comes with the accessory kit.

This is used as a counterhold.

42
IMG-450097
 

Install components that come with the accessory kit.

Tighten the nut.

Use hands only.

43
IMG-450098
 

Reinstall the removed part.

44
IMG-450105
 

Position/route the cable as illustrated.

Install the cable.

Use a cable tie

45
IMG-450112
 

Note!
Orientation view

Ground connection

46
IMG-466585
 

Release the catches.

Loosen the marked detail.

47
IMG-466592
 

Remove the nut.

48
IMG-466616
 

Position/route the cable as illustrated.

49
IMG-466614
 

Connect the prerouted cable.

50
IMG-466619
 

Install the marked component.

Ensure that all clips engage.

51
IMG-466528
 

Install the nut.


Tightening torque: M6 , 10 Nm

 

Installation

52
IMG-448507
 

Reinstall the removed part.

Reinstall the screws.

53
IMG-448509
 

Reinstall the removed part.

54
IMG-448504
 

Reinstall the removed part.

Reinstall the screws.

55
IMG-448510
 

Reinstall the removed part.

 

Accessory installation

56
IMG-441390
 

Lubricate the O-ring.

Use: 1161427, Low temperature grease

57
IMG-440316
 

Lubricate the O-ring.

Use: 1161427, Low temperature grease

58
IMG-462890
 

Install the marked component.

Install the catch.

59
IMG-462893
 
  1. Passenger Compartment Connector Cable

  2. Engine heater cable

60
IMG-462892
 

Install components that come with the accessory kit.

  1. Passenger Compartment Connector Cable

  2. Engine heater cable

61
IMG-462897
 

Place the cable tie as illustrated.

62
IMG-466778
 

Note!
Orientation view

63
IMG-466780
 
64
IMG-466655
 

Position/route the cables as illustrated.

65
IMG-466651
 

Install the cables.

66
IMG-462912
 

Note!
Orientation view

  1. Passenger Compartment Connector Cable

  2. Engine heater cable

67
IMG-466656
 

Place the cable tie as illustrated.

Position/route the cables as illustrated.

Tighten the cable tie.

68
IMG-462921
 

Install a clips onto the upper edge of the subframe.

Position/route the cables as illustrated.

Install the cables.

69
IMG-462925
 

Place the cable tie as illustrated.

Position/route the cables as illustrated.

Tighten the cable tie.

70
IMG-465304
 

Note!
Orientation view

  1. Passenger Compartment Connector Cable

  2. Engine heater cable

  3. Steering gear

  4. Cable harness

71
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.

72
IMG-466492
 

Remove the screws.

73
IMG-464686
 

Clean the surface.

74
IMG-466482
 

Note!
Orientation view

75
IMG-466493
 

Install components that come with the accessory kit.

Tighten the screw.

76
IMG-465576
 

Remove the protective film.

77
IMG-466494
 

Install component that comes with the accessory kit.

78
IMG-466497
 

Press the marked component.

79
IMG-466498
 

Install components that come with the accessory kit.

Tighten the screw.

80
IMG-441390
 

Lubricate the O-ring.

Use: 1161427, Low temperature grease

81
IMG-464692
 

Connect the cable.

Install the catch.

82
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.

83
IMG-465993
 

Tighten the cable ties.

84
IMG-466809
 

Remove the clip.

Remove the screw.

85
IMG-453670
 

Remove the nuts.

86
IMG-453671
 

Fold the wing liner aside.

87
IMG-453672
 

Remove the marked part.

88
IMG-386950
 

Remove the nut.

Fold the insulation aside.

89
IMG-402286
 

Make a cut in the insulation.

90
IMG-386951
 

Remove the marked part.

The part is not to be reused.

91
IMG-453673
 
92
IMG-453674
 

Pull the wiring through.


Use special tool: T9814204, Expander pliers

93
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.

94
IMG-453681
 

Refit the insulation.

Install the nut.

95
IMG-453678
 

Position/route the cable as illustrated.

Install the cable.

Use a cable tie

96
IMG-463188
 

Position/route the cable as illustrated.

97
IMG-453584
 

Note!
Do not fully tighten the bolt.

Reinstall the removed part.

Install components that come with the accessory kit.

98
IMG-441390
 

Lubricate the O-ring.

Use: 1161427, Low temperature grease

99
IMG-453585
 

Install components that come with the accessory kit.

100
IMG-453586
 

Install components that come with the accessory kit.

101
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.

102
IMG-453593
 

Fold the carpet aside.

Remove the screws.

Fold marked part aside.

103
IMG-453600
 

Tighten the screw.


Tightening torque: M6 , 10 Nm

104
IMG-453594
 

Install the marked component.

Reinstall the screws.

105
IMG-432205
 

Make a cut in the insulation.

Remove the insulation material.

Fold the floor carpet back.

106
IMG-453596
 

Install component that comes with the accessory kit.

Note the position.

 

Installation

107
IMG-400000
 

Reinstall the removed parts in reverse order.

108
IMG-456337
 


Tightening torque: Aluminum wheel rim to wheel hub
Stage 1: 4 Nm
Stage 2: 50 Nm
Stage 3: 140 Nm