Installation Instruction

Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
V40 2019
V40 (13-) 2019 D4204T13 M76, V40 (13-) 2019 D4204T13 TF-71SC, V40 (13-) 2019 D4204T16 M76, V40 (13-) 2019 D4204T16 TF-71SC

Instruction NoVersionPart. No.Click to download PDF-version of this Installation Instruction
307959181.031373665
Electric engine heater (R-design) (Vehicles with urea, variant code G102)




IMG-454214




 

Special tools

 

951 2955 Cover

Tool number:951 2955

Tool description:Cover

Tool boards:20

 

951 2957 Coolant Reservoir

Tool number:951 2957

Tool description:Coolant Reservoir

Tool boards:20

 

981 4192 Hose

Tool number:981 4192

Tool description:Hose

Tool boards:EU99


Materials

Designation

Part number

Rust inhibitor, low viscosity

Low temperature grease

1161427


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

IMG-454129

IMG-448651


 
 

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.

2
 

There may be parts in the accessories kit that are not needed for this installation.

 

Color symbols

3
IMG-363036
 

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.

 

Removal

4
IMG-332193
 

Set the ignition key to position 0.

5
IMG-362805
 

Open the hood.

6
IMG-362807
 
7
IMG-368369
 
8
IMG-368376
 

Remove the screws.

9
IMG-362811
 

Remove the nut.

10
IMG-371233
 

Fold the wing liner to one side.

 

Accessory installation

11
IMG-372264
 

Clean the Bumper Cover surface.

12
IMG-386343
 

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

13
IMG-372272
 
14
IMG-372273
 
15
IMG-372275
 

Use tape

16
IMG-372276
 

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.

17
IMG-448694
 
  1. Use a drill with the stated size

  2. Use: Air-powered keyhole saw

18
IMG-448702
 

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.

19
IMG-383193
 
20
IMG-362843
 

Pull the wiring through.

21
IMG-363401
 

Note! Ensure that the protective cover is turned the right way.

22
IMG-448713
 

Note!
Do not fully tighten the nut yet.

Install components that come with the accessory kit.

23
IMG-448714
 

Install component that comes with the accessory kit.

This is used as a counterhold.

24
IMG-448715
 

Tighten the nut.

Use hands only.

 

Removal

25
IMG-358506
 

Raise the car.

  1. Remove the clips.

  2. Remove the screws.

26
IMG-358531
 

Remove the marked part.

27
IMG-386654
 

Loosen the hose clamp.

The part is to be reused.

28
IMG-386655
 

Fold marked part to one side.

29
IMG-386007
 

Remove the screw.

The part is to be reused.

30
IMG-385808
 

Remove the nut.

The part is to be reused.

31
IMG-386656
 

Remove the part carefully

32
IMG-386658
 

Remove the marked part.

33
IMG-371659
 

Note!
Orientation view

34
IMG-371658
 

Note!
Close the drain cock after the coolant has drained.

Place a container under the car.

Drain the coolant.

 

Accessory installation

35
IMG-383219
 

Note!
Orientation view

36
IMG-383289
 

Use a drill with the stated size

Install components that come with the accessory kit.

Tighten the screw.

Use: , Rust inhibitor, low viscosity

37
IMG-383291
 
38
IMG-383221
 

Place the cable tie as illustrated.

Position/route the cable as illustrated.

Tighten the cable ties.

39
IMG-383226
 

Note!
Orientation view

40
IMG-387205
 

Install the clip(s).

Tighten the cable ties.

41
IMG-383229
 

Note!
Orientation view

42
IMG-383230
 

Tighten the cable tie.

43
IMG-448680
 

Caution!
No grease on contact surfaces.

Lubricate the O-ring.

44
IMG-387266
 

Connect the cable.

Install the catch.

45
IMG-387258
 

Tighten the cable ties.

46
IMG-383266
 

Note!
Orientation view

47
IMG-448671
 

Remove the nut.

The part is to be reused.

48
IMG-448665
 
49
IMG-448666
 

Loosen the hose clamp.

The part is to be reused.

Place a container under the car.

Undo the hose from the connection.

50
IMG-386051
 
51
IMG-387283
 

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

52
IMG-448636
 

Assemble components that come with the accessory kit.


Tightening torque: M6 , 10 Nm

53
IMG-448670
 

Attach the hose clamps.

Install the hoses.

Tighten the hose clamps.

54
IMG-448674
 

Place the component where indicated in the graphic.

Attach the hose clamp

Connect the hose.

Install the hose clamp

55
IMG-448673
 

Install the nut.


Tightening torque: M8 , 24 Nm

56
IMG-454117
 

Note!
Orientation view

57
IMG-454122
 

Place the cable tie as illustrated.

Position/route the cable as illustrated.

Tighten the cable tie.

  1. Steering gear

  2. Subframe

58
IMG-454124
 

Note!
Orientation view

  1. Steering gear

  2. Heat deflector plate

59
IMG-454166
 

Place the cable tie as illustrated.

Position/route the cable as illustrated.

Tighten the cable tie.

60
IMG-386360
 

Remove any excess.

61
IMG-454140
 

Clamp using the grey cable tie.

62
IMG-454135
 
  1. Remove the marked part.

  2. Install component that comes with the accessory kit.

63
IMG-454142
 

Place the cable tie as illustrated.

Position/route the cable as illustrated.

Tighten the cable tie.

64
IMG-448677
 

Caution!
No grease on contact surfaces.

Lubricate the O-ring.

Use: 1161427, Low temperature grease

65
IMG-383271
 

Connect the cable.

Install the catch.

 

Installation

66
IMG-363206
 

Fill the cooling system according to the service information in VIDA:

Information / Repair / Cleaning, Inspection and Adjustment / 2 Engine with mountings and equipment / 26 Cooling system / 261 radiator and connections / Cooling system – draining, charging and bleeding.


Use special tool: T9512955, Cover

Use special tool: T9512957, Coolant Reservoir

Use special tool: T9814192, Hose

67
 

Reinstall the removed parts in reverse order.

68
IMG-370207
 
69
IMG-370203