Installation Instruction

Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
XC90 2010
XC90 (03-) 2010 B8444S

Instruction NoVersionPart. No.Click to download PDF-version of this Installation Instruction
306619481.131267440
Fuel-driven heater V8




 
Equipment
A0000162
A0000163
A0000161
A0000179
A0000172
A0801178

IMG-222700

IMG-222701

IMG-223000

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!

This accessory requires software unique to the car.


1
R8504235
 

    Applies to cars with two rows of seats

  • Remove the front floor hatch. Lift it up approx. 50 mm and then pull it out from its mountings in the front edge.

2
R8504236
 

    Applies to cars with two rows of seats

  • Lift out the front storage box.

3
R8504241
 


Note!

Removal of the right-hand seat in the second row (steps 3-8) applies to all cars. For cars with three rows of seats, the left-hand seat and centre seat of the second row must also be removed. See step 9.


  • Remove the panel on the right rear mounting on the right-hand front seat. Prise up the rear edge of the panel slightly and then pull rearwards and upwards.

4
R8504169
 

  • Slide the seats of the first row as far forward as possible.

  • Carefully prise loose and remove the panel over the joint between the door sills on the right side.

5
R8504171
 

  • Remove the panel for the right front seat mounting of the second row's right-hand seat by pressing down the catch (1) on top and pulling the panel forward. Remove the screw underneath.

6
R8504243
 

  • Remove the panel for the front seat mountings of the second row's right-hand seat/centre seat by pressing down the catches (1) on top and pulling the panel forward. Remove the screw for the right-hand seat.

7
R8504247
 

  • Lower the backrest of the right-hand seat in the second row.

  • Remove the cover (1) of the rear seat mountings of the right-hand seat by prising the rear edge loose. Remove the screws.

8
R8504234
 

  • Undo the sill panel of the right rear door. Pull the rear edge until the clips release. Continue forward until the remaining clips release.

  • Unhook the sill trim panel from the B-post panel. Place the sill trim panel in the cargo compartment.

  • Remove the seat.


Caution!

Exercise care when lifting the seats out of the passenger compartment so the mountings do not damage the door panels.


9
R8504231
 

    Applies to cars with three rows of seats

  • Remove the corresponding panels and screws on the left-hand side and for the left-hand and centre seat of the second row following steps 3-8.

  • Unplug the connector for the centre console.

  • Remove the left-hand and centre seat.


Caution!

Exercise care when lifting the seats out of the passenger compartment so the mountings do not damage the door panels.


  • Remove the air nozzles on the right and left-hand side.

10
R8504237
 

Applies to cars with two rows of seats

  • Bend aside the floor mat and secure it with the seat belt on the left-hand side.

  • Carefully bend aside the styrofoam insulation to provide access to the cover of the tank unit.


Caution!

Take care. The styrofoam insulation comes off easily.


11
IMG-222702
 

    Applies to cars with three rows of seats

  • Bend aside the floor mat and the insulating mat.

  • Use a screwdriver or the like to hold the mat in place.

  • Remove the right-hand section of the air duct.

  • Remove both panels of styrofoam insulation.

12
R8504239
 

  • Remove the four nuts in the tank unit cover.

  • Carefully prise loose the cover using a weatherstrip tool.

13
R2501320
 

The tank should be lowered in order to facilitate the installation of the suction line.

  • Remove the two screws (1) in the fuel tank front mountings. If necessary, screw out the screw (2) to the fuel filter.

14
R2501321
 

  • Unscrew the two screws (1) holding the tank's rear mounting, screw them out as far as possible without removing them.

15
R2302950
 

  • Drill out the connection (1) in the tank unit with a Ø4 mm (5/32") diameter drill bit. Apply vaseline to the drill bit to prevent swarf falling into the fuel tank.


    Caution!

    Use a compressed air power drill. An electric power drill must not be used due to the risk of sparks.


16
R2302951
 

  • Insert the pipe (1) from the kit into the connection (2). Press the pipe down until it is in contact with the connection. If necessary, use a hammer and drift to drive down the pipe.

  • Take the fuel line with electrical line from the kit. Affix protective tape over the hole on the end of the fuel line that is to be inserted through the hole in the floor (the one with the short, unconnected line end).

  • Guide the whole line assembly (3) between the floor and the fuel tank out to the right-hand side of the car.

17
R2302952
 

  • Press the quick-release connector (1) onto the connection until a click is heard. Check that the quick-release connector is secure.

18
R3702953
 

    Applies to cars with two rows of seats

  • Carefully bend up the end of the styrofoam insulation.

  • Place a spacer underneath.

    Applies to all models

  • Route the line previously routed together with the fuel line under the seat frame and connect it to the front connector (1) in the contact bridge (2).

    Applies to cars with two rows of seats

  • Remove the spacer and bend down the styrofoam insulation.

    Applies to all models

  • Place the line in the holder in the tank unit cover.

  • Reinstall the tank unit cover and secure with the four nuts.

19
 

    Applies to all models

  • Refit the styrofoam insulation panels.

    Applies to cars with three rows of seats

  • Reinstall the air duct.

    Applies to all models

  • Fold back the carpet.

    Applies to cars with three rows of seats

  • Reinstall the air nozzles under the outer seats.

    Applies to all models

  • Reinstall the seats.


    Caution!

    Exercise care when lifting the seats into the passenger compartment so the mountings do not damage the door panels.


  • Plug in the connector for the centre console.

  • Install the mounting screws for the seats and torque tighten them to 48 Nm (35 lbf.ft.).

  • Refit the panels and the covers over the seat mountings.

  • Refit the panels over the joints between the door sills.

    Applies to cars with two rows of seats

  • Refit the front storage box.

  • Refit the front floor hatch.

20
R2302954
 

  • Route the fuel hose with wiring harness (1) forward in the rear edge of the fuel tank. Route it along the fuel tank's right side and forward. Let it hang down.

21
IMG-222703
 

  • Undo the rail for the fuel line by inserting a small screwdriver in the small hole between the rail and the clips. Move the clips in the same direction as the oblong hole in the rail. The rear clip has a small spot on the clip where you position the screwdriver and move it forward.

22
R2501322
 

  • Take the fuel pump with line from the kit. Insert the line in the front edge of the fuel tank's right side.

  • Route the fuel line so that is next to the existing fuel line in the cut-out on top of the fuel tank. Then position the fuel line on the right-hand side of the wiring which runs to the engine compartment.

  • Pull up the wiring so that the fuel pump (FP) is positioned as approximately as illustrated.

23
R2501323
 

  • Remove the brake pipe (1) from the clamp.

  • Take the fuel pump with bracket and place the bracket on the top of the fuel tank mounting bracket in front of the small holes for the blind rivets.

  • Blind rivet the fuel pump bracket using two metal blind rivets (2).

24
R2302955
 

  • Use a double clamp from the kit to clamp the two fuel lines from the fuel pump to each other at the two blue markings on the fuel lines.

  • Press the brake pipe back into the clamp.

  • Install the two screws holding the tank. Install the screw to the fuel filter if it was detached. Torque tighten the five screws to 24 Nm (18 lbf.ft.).

  • Connect the connector (1) from the pre-routed power cable to the fuel pump (FP).

  • Connect the quick-release connector (2) on the pre-routed fuel line to the fuel pump (FP).

25
R2302956
 

  • Clamp in the fuel line at the brake pipe using a double clamp (1).

26
IMG-222704
 

  • Press into place the fuel hose from the recently installed fuel pump (FP). Press into place in the bottom of the rail and forwards, in the cut-out furthest to the right.


    Note!

    The marking on the fuel hose must be 25 mm inside the edge of the rail where the fuel hose enters the rail.


27
IMG-222705
 

  • Slide back the retaining clip for the rail. Press the rail against the car body. Ensure that the rail is securely installed.

28
IMG-222902
 

  • Remove the left front wheel.

  • Drill off the heads of the five blind rivets (1) holding in the wing liner using a Ø6 mm (1/4") diameter drill bit.

    Remove:

  • the clip (2) in the lower edge of the bumper

  • the plastic nuts (3) holding the wing liner in place

29
R8600966
 

  • Undo the wing extension by carefully prising loose the lower corner using a weatherstrip tool.

  • Pull it loose up to the highest point of the wheel housing until the three catches in the lower edge and the two clips a little higher up have released.

    Applies to cars with the accessory side decor

  • Bend aside only the retaining lugs on the side decor of the front wing so that the edge of the wing liner can be released.


    Note!

    Do not undo the side decor of the front wing.


30
R8600961
 

  • Remove the bumper's left-hand panel by carefully pulling it away at the left-hand lower edge until the two catches down on the inside release. Continue to pull until the clips release all around.

31
R8600965
 

  • Bend aside the wing liner and secure it with a tie strap or the like.

  • Remove the remains of the rivets.

32
IMG-222706
 

  • Remove the six screws and the engine splash guard.

33
R2102465
 

  • Remove the front splash guard. First remove the six screws on the underside.

  • Then lift the splash guard up so that the front/upper mounting's guide sleeve releases. Forcefully push the left-hand side of the skid plate forward towards the bumper cover. Push the corner forward until the splash guard's left-hand fixture mounting lug releases from the subframe.

  • Repeat on the right-hand side.

34
IMG-222707
 

  • Insert the fuel pipe with the four pre-mounted clips (1) from the front, between the engine and the subframe. Press it in with the clips in the front edge of the subframe. There is not much space for inserting the fuel pipe and it requires bending and twisting slightly to reach its position.

35
IMG-222708
 

  • Press in the fuel pipe into the bottom of the two clips (1) that hold the servo pipes.

  • Check that the fuel pipe does not catch on the subframe. Check that the fuel pipe does not rub against pipes or screw heads for the suspension.

36
IMG-222709
 

  • Unplug the connector (1) on the circulation pump.

  • Install a sealing plug in the connector and secure the cable above the top of the panel (2) using a tie strap.

37
IMG-222710
 

  • Install hose pliers on the hose at each connection.

  • Detach the hose clamps and remove the hoses.

38
IMG-222711
 

  • Install a workshop hoist (1) under the front edge of the subframe.

  • Take the weight off the subframe.

  • Remove the screw and circulation pump with bracket from the subframe mounting.

39
R8703683
 

  • Install the heater (1) on the bracket (2) with two M8 screws (3). Tighten.

40
R8703684
 

  • Take a small hose clamp for the fuel line from the kit. Install the clamp on the fuel hose (1) from the fuel pipe on the subframe.

  • Remove the protective cap on the inlet (2).

  • Raise the heater into its installation position.

  • Press in the fuel line on the inlet (2) on the heater and squeeze the hose clamp together.

41
R8703685
 

  • Take a new screw (1) from the kit and tighten in the heater on the subframe mounting. Do not tighten hard yet.

  • Take the metal bracket and two nuts from the kit.

  • Position one of the metal bracket's retaining lugs on the stud (2) of the heater and fit the nut. Tighten loosely.

  • Position the other retaining lug of the bracket on the stud (3) and fit the nut.

  • Tighten the nuts.

  • Torque tighten the screw (1) to 105 Nm (78 lbf.ft.). Then angle tighten it to 120° or max. 280 Nm (206 lbf.ft.).

  • Remove the protective cap from the pre-routed connector (4). Press in the catch on the top and pull it off.

  • Connect the cable from the heater to the connector.

42
IMG-222712
 

  • Thread the chafe guard onto the short fuel pipe.

43A
IMG-223741
43B
IMG-222713
 

Illustration A

  • Insert the end of the short fuel pipe that is bent at two different levels (illustration A), under the steering gear and anti-roll bar, on the top of the subframe's right-hand rear corner (illustration B).

Illustration B

44
IMG-222714
 

  • Take a hose clamp (1) and thread it on the short fuel line on the subframe.

  • Connect the short fuel pipe to the fuel line. Slide the pipe into the fuel line. Slide the pipe in so far that the two pipes are in contact with each other. This prevents air pockets from forming.

  • Squeeze the hose clamp together.

  • Take a tie strap with clip and install the clip in the hole (2) on the subframe. Tighten the tie strap around the fuel line.

45
IMG-222715
 

  • Thread a hose clamp on the fuel line.

  • Connect the fuel line to the short fuel pipe.

  • Tighten the hose clamp.

  • Install two small tie straps in each end of the chafe guard. Check that the pipe does not chafe against the anti-roll bar mounting.

46
IMG-222716
 

  • Secure the heater's fuel line by the car's fuel lines using two double clamps. Check that the fuel line does not chafe against any sharp edges.

47
IMG-222717
 

  • Install an edge protection strip on the panel edge where the heater hoses shall run from the engine compartment out to the heater.

48
IMG-222718
 

  • Connect the heater hoses to the heater.

  • Tighten the hose clamps. Make sure that none of the hose clamps chafe against the heater hoses.

  • Remove the hose pliers.

49
IMG-222719
 

  • Secure the hoses using a tie strap threaded through two holes in the member.


    Note!

    Do not tighten so hard that the hoses are deformed.


50
 

  • Reinstall the skid plate and torque tighten to 50 Nm (37 lbf.ft.).

  • Reinstall the engine splash guard and torque tighten to 25 Nm (18 lbf.ft.).

  • Fold back the wing liner. Install the nuts and tighten.

  • Press the wing extension into place.

  • Take blind rivets from the kit to rivet the front edge of the wing liner into place.

  • Refit the bumper panel.

  • Reinstall the clip in the lower edge of the bumper.

  • Remount the wheel and tighten the bolts to 140 Nm (103 lbf.ft.)

  • Fill with fluid.

  • Start the engine and bleed the cooling system.

  • Program the software and test run the heater in accordance with the service information in VIDA.