Installation Instruction

Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
XC90 2010
XC90 (03-) 2010 D5244T5 M66 AWD, XC90 (03-) 2010 D5244T4 M66 AWD

Instruction NoVersionPart. No.Click to download PDF-version of this Installation Instruction
307803671.131267444
Fuel-driven heater, D5244T, M66




R8703687




 
Equipment
A0000162
A0000163
A0000161
A0801178
A0000166
A0000172

IMG-245458

M8703808


 
  

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
A8800136
 

  • Turn the ignition switch to position 0.

  • Disconnect the battery negative lead.


    Note!

    Wait at least five minutes before disconnecting the connectors or removing other electrical equipment.


2
R8504235
 

    Applies to cars with two rows of seats

  • Remove the front floor hatch by first lifting it up a bit and then pulling it out of the mountings in the front edge.

3
R8504236
 

    Applies to cars with two rows of seats

  • Lift out the front storage box.

4
R8504241
 


Note!

Removal of the right-hand seat in the second row (steps 4-9) 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 10.


  • 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.

5
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.

6
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.

7
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.

8
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.

9
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.


10
 

    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.

  • 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.


11
R8504231
 

    Applies to cars with three rows of seats

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

12A
R8504237
12B
R8504238
 

Illustration A 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.


Illustration B 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 air duct.

  • Remove both panels of styrofoam insulation.

13
R8504239
 

  • Remove the four screws in the tank fitting cover.

  • Carefully prise loose the cover using a weatherstrip tool.

14A
R2501320
14B
R2501321
 

  • Remove the four screws (1) from the front and rear mountings of the fuel tank so that the tank is lowered a bit in order to fit a suction line to the fuel tank. If necessary, loosen and unscrew the fuel filter screw (2) to lower the fuel tank even more.

15
R2302950
 

  • Drill the connection (1) in the tank fitting with aØ 4 mm (5/32”) drill bit.


    Note!

    Use a compressed air drill with a greased bit.


16
R2302951
 

  • Insert the pipe (1) from the kit down into the connection (2). Press the pipe down until it is flush with the connection.

  • Take the fuel line with electrical line from the kit. Affix protective tape 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).

  • Insert the whole line assembly (3) between the floor and the fuel tank out to the right.

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 fold down the styrofoam insulation.

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

  • Refit the tank fitting cover and secure with the four screws.

19
 

  • Refit the styrofoam insulation panels.

  • Applies to cars with three rows of seats: Refit the air duct.

  • Fold back the carpet.

  • Applies to cars with three rows of seats: Refit the air nozzles under the outer seats.

  • Reinstall the seats.


Caution!

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


  • Secure the seats, tightening the screws 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
D2302957
 

  • 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
R2303046
 

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

22
D2302958
 

  • 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
D2302959
 

  • 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.

  • Use two metal pop rivets (2) from the kit to rivet the fuel pump bracket at the fuel tank mounting bracket.

24
D2302960
 

  • 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.

  • Tighten the four screws that hold the tank in place. Tighten the screw of the fuel filter if this was loosened. Tighten the 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
D2302977
 

  • Use a double clamp from the kit to clamp the fuel line at the fuel pipe at point (1).

26A
R2303048
26B
R2303062
 

  • 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 opposite the point where the fuel hose goes into the rail.


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

27
IMG-245459
 

  • Remove the left front wheel.

  • Drill out the five pop rivets (1) holding the fender liner in place and the pop rivet (2) in the bottom edge of the bumper. Use a Ø6 mm (1/4”) drill bit.

  • Remove any rivet remains.

28
IMG-245460
 

  • Remove the three plastic nuts holding the small plate, and the cover panel over the left-hand driveshaft.

  • Remove the plates and cover panel.

29
R8600966
 

    Applies to cars with the accessory side decor


  • Note!

    Do not undo the side decor of the front wing.


    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.

    Applies to cars without the accessory side decor

  • 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.

30
R8600961
 

  • Remove the left bumper panel by carefully prising it loose in the left bottom edge until the clips on the bottom and inside release. Continue pulling until the clips all around release.

31
R8600965
 

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

32
R2000348
 

  • Remove the protective engine plate (1) by removing the screws (2).

33
R2102465
 

  • Remove the front skid plate by first removing the six screws (1) on the bottom.

  • With the aid of a helper, pull the skid plate forward. Pull one corner until one of the skid plate retaining lugs releases from the sub-frame. Then undo the other corner. At the same time, it may be necessary to carefully bend down the bottom edge of the bumper lining.

  • Open the cover for the cooling system's expansion tank.

  • Thread a hose onto the engine coolant drain nipple.

  • Open the drain nipple. Drain off the coolant.

34
R2303064
 

  • Pull off and push the pipe elbow to one side so that the fuel pipe can be positioned.

35
R2303065
 

  • Remove the power steering pipes and the plastic hose from their clips to make installing the fuel pipe easier. In order to push the upper power steering pipe to one side, the rubber coated clamp on the upper side of the front edge of the sub-frame may need to be removed.

36A
R2303047
36B
R2303066
 

  • Take the fuel pipe with the four pre-mounted clips (1) from the kit and fit it to the sub-frame. Insert it between the loosened pipes and the sub-frame. Press it into place with the clips in the sub-frames front edge and in the bottom on the clips (2) holding the plastic hose in place. The space is tight, so the fuel pipe must be bent and twisted to get it into place.

  • Refit the power steering pipes and press the plastic hose into place on the outside of the fuel pipe. Refit the rubber-coated clamp if it was removed.

  • 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.

37
R6400811
 

  • Reinstall the pipe elbow.

  • Position the workshop lift (1) under the front edge of the sub-frame.

  • Take the weight off the subframe.

  • Remove the screw (2) and washer (3) from the left front mounting on the sub-frame.

38
R8703683
 

  • Fit the heater (1) on the bracket (2) with the screws (3) from the kit and tighten.

39
R8703684
 

  • Raise the heater into its installation position.

  • 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.

  • Press the fuel line on the inlet (2) on the fuel pump (FP). Tighten.

40
R8703685
 

  • Take a new screw (1) from the kit and secure the heater to the left front corner of the sub-frame. 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 heater to the sub-frame and bracket. Tighten the screw (1) to 105 Nm (78 lbf.ft.). Angle tighten 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.

41
R2303052
 

  • Take the chafing protection and short fuel pipe from the kit. Fit the chafing protection on the pipe.

42
R2303067
 

  • Insert the end of the fuel line, which is kinked in two places, under the power steering and the anti-roll bar, on top of the rear right corner on the sub-frame.

43
R2303068
 

  • Take a hose clamp from the kit. Thread the hose clamp onto the short fuel line on the fuel pipe on the sub-frame.

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

  • Squeeze the hose clamp together.

44A
R2303069
44B
R2303070
 

Illustration A

  • Take a tie strap from the kit. Clamp the protective tube at the fuel pipe so that it is securely installed.

Illustration B

  • Take a hose clamp from the kit. Thread it on the fuel line to the fuel pump that was routed previously. Connect the fuel line to the short fuel pipe. Slide the pipe in so that the two pipes are in contact with each other. This prevents air pockets from forming.

  • Ensure that the fuel line is routed correctly and does not obstruct the plastic hose or rub against the sub-frame or other components.

  • Squeeze the hose clamp together.


    Note!

    Fuel lines and fuel pipes must be at least 15 mm (19/32") from brake pipes.


45
R2303071
 

  • Take a tie strap from the kit and clamp the fuel pipe at the plastic hose.

46
R2303072
 

  • Take a double clamp from the kit and clamp the fuel line for the parking heater at the ordinary fuel line.

47
R2501365
 

  • Remove the two screws (1) from the induction pipe of the air filter.

  • Remove the induction pipe and put it aside.

48
IMG-245461
 

  • Remove the engine cover by pulling it up at the front edge and unhooking it at the rear.

49
IMG-245464
 

  • Slacken off the five screws in the stay between the suspension turrets. Remove the stay.

50
IMG-245465
 

  • Remove the cover from the air filter.

51
IMG-245466
 

  • Press in the catches on the connectors to the control module on the air filter, turn the handle and remove them.

52
IMG-245467
 

  • Disconnect the connector and the hose clamp on the pipe to the air filter.

53
IMG-245480
 

  • Slacken off the plastic nut (1) on the air filter's left-hand bracket. Pull off the air filter from the frame member, fold it up and position it so that the heater hoses can be pulled out.

54
IMG-245502
 

  • Disconnect the quick-release connector on the left heating hose (1) for the passenger compartment heater by pressing in the locking rings' two hooks. Twist the quick-release connector and withdraw it.

  • Remove the heater hose on the cooling pipe by the left-hand side of the rear edge of the cylinder head.

  • Remove the heater hose. It shall not be re-used.

55
IMG-245503
 

  • Take the heater hoses from the kit and route them down at the front edge of the transmission out to the front edge of the left-hand wheel arch.

  • Route the hoses backwards along the inside of the left-hand frame member. Continue to route them up to and against the rear side of the pipe to the turbocharger.

  • Connect the hose with the quick-release connector to the cut-out in the cowl panel.

  • Connect the remaining hose end to the cooling pipe (1) at the left-hand side of the rear edge of the cylinder head. Tighten using a hose clamp from the kit. Ensure that the hoses do not come into contact with moving parts or sharp edges in the engine compartment.

56
IMG-245504
 

  • Take the rubber coated clamp and M8*16 screw from the kit.

  • Clamp the heater hose from the cowl panel. Tighten the clamp by the existing holes in the end of the transmission above the driveshaft.

  • Torque tighten the screw to 24 Nm (18 lbf.ft.).

57
R8703686
 

  • Connect the two heater hoses (1) to the heater using the hose clamps from the kit and tighten.

58
 

  • Tighten the drain nipple on the radiator. Remove the hose.

  • Refit the front skid plate and tighten to 50 Nm (37 lbf.ft.)

  • Fold the fender liner back into position. Install the small plate and cover panel over the driveshaft with the plastic nuts and tighten.

  • Press the wing extension into place.

  • Use the pop rivets from the kit to rivet the front/lower edge of the wing liner into place.

  • Refit the bumper panel.

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

59
 

  • Fill with coolant. Reinstall the expansion tank cap.

  • Refit the air filter and reconnect disconnected cables or hoses.

  • Install the air filter in the fender liner. Use the plastic nut.

  • Refit the induction pipe on the front plate between the headlamps. Tighten the screws to 10 Nm (7 lbf.ft.)

  • Connect the connectors to the control module on the air filter.

  • Refit the cover over the air filter.

  • Reinstall the stay between the suspension turrets. Tighten the four x M10 screws to 50 Nm (37 lbf.ft.) and the M12 screw to 80 Nm (59 lbf.ft.).

  • Reconnect the battery negative lead

  • Start the engine and bleed the cooling system. Check that there is no leakage.

  • Reinstall the engine splash guard and torque tighten the screws to 25 Nm (18.5 lbf.ft.)

  • Reinstall the engine cover.

  • Programme the software in accordance with the service information in VIDA.

  • Test the function of the heater according to separate instructions.