Installation instructions, accessories - Parking heater S60 / V70. Volvo Car Corporation Göteborg, Sweden. Section Group Weight(Kg/Pounds) Year

Transcription

1 S60 / V70 Section Group Weight(Kg/Pounds) Year Month R Page 1 of 19

2 Required tools A A A A A A M M Page 2 of 19

3 Any comments on this publication? Please contact your nearest dealer. Thank you! Publication no: MA , Issue: Comments: From:... Address:... Telephone no:.... Telefax:... Page 3 of 19

4 INTRODUCTION NOTE! Read through the entire text before carrying out any work. Parking heater Note! This accessory requires software unique to the car. The front page gives the date of this edition and the edition it replaces The second page shows the tools needed for the installation and the contents of the installation kit The illustrations display the procedure in order of operation. The order of operation is repeated in the text section Cut out the text page in order to follow the illustrations and text at the same time. Page 4 of 19

5 1 Interior preparations (V70 XC) Fold the centre seat cushion (1) forwards. Fold the centre backrest (2) forwards by pressing the lever (3) away from you. M Interior preparations (V70 XC) Remove the centre backrest. First pull the handle at the top of the reverse of the backrest. Then pull the backrest upwards. M Interior preparations (V70 and V70 XC) Fold the right-hand rear seat cushion forward. M Interior preparations (V70 and V70 XC) Fold the right-hand rear backrest forward. A Page 5 of 19

6 5 Interior preparations (V70 and V70 XC) Remove the right-hand side cushion. First pull the top edge (1) towards you. Then lift the side cushion upwards (2). A Interior preparations (S60) Remove the rear seat cushion (1). Pull the cushion up at the front and then forwards. D Interior preparations (S60) Fold the right-hand rear backrest forwards Remove the seat belt from the guide (1). M Interior preparations (S60) Remove the clip (1) at the side of the right-hand side cushion Pull out the top edge of the left front panel in the cargo compartment to access the upper catch for the side cushion. M Page 6 of 19

7 9 Interior preparations (S60) Remove the right-hand side cushion. First press in the catches (1) at the top edge of the reverse of the side cushion. Pull the cushion out slightly Grasp the cushion using both hands. Twist the cushion clockwise until the catches on the inside release Remove the side cushion. First pull out the top of the side cushion. Then pull upwards. M Interior preparations (all models) Applies to cars with mountings for Isofix on the right side of the rear seat Remove the screws (1). Slacken off the end mounting (2) for the seat belt Remove the nut (3) and the washer (4) from the stud Remove the mounting (5). M Interior preparations (all models) Disconnect the connector (1) and the screw (2) on the right backrest Lift up the mounting (3). Gently work the backrest backwards and forwards to release the pin from the mounting in the left backrest Remove the right backrest. D Interior preparations (all models) Push the insulation panel to one side so that the cover (1) is accessible Remove the nuts (2) and the cover Drill out the connection (3) in the fuel tank unit (4). Use a Ø4 mm (5/32 ) diameter drill bit. Note! D Use a compressed air power drill with a greased bit. Page 7 of 19

8 13A Interior preparations (all models) Illustration A displays the front mounting Illustration B displays the rear mounting Remove the four screws (1) in the front and rear mountings so that the fuel tank is lowered slightly. This allows the suction pipe for the fuel tank to be installed. If necessary, remove the screw (2) for the fuel filter to lower the fuel tank further. R B R Interior preparations (all models) Insert the pipe (1) (from the kit) into the connection (2). Press the pipe down until it is in contact with the connection Take the fuel line with the power cable from the kit. Apply tape to the end on the section of the fuel line which is to be inserted through the hole in the floor. (The one with a short free end.) M Insert the whole pipe assembly (3) between the floor and the fuel tank out to the right. 15 Interior preparations (all models) Press the quick-release connector (1) onto the connection until a click is heard. Check that the quick-release connector is secure Connect the power cable, routed with the fuel line to the connector (2) in the connector bridge (3). M Interior preparations (all models) Position the wiring in the rubber grommet in the cover. Reinstall the cover. Tighten the cover using the four nuts. Page 8 of 19

9 Applies to cars with Isofix mountings Reinstall the Isofix mounting and seat belt buckle Tighten the screw. Tighten to 40 Nm (30 lbf.ft.).tighten the nut. Tighten to 30 Nm (22 lbf.ft.). Applies to all models Reinstall the backrests, side cushions and seat cushions Open the cover for the radiator expansion tank. 17 Route the fuel hose and cable harness (1) at the rear edge of the fuel tank. Route it forwards along the right-hand side of the fuel tank. Leave it hanging down. R Detach the fuel rail (1) at the front edge. First insert a small screwdriver into the small hole between the yellow clip and the fuel rail. Push the clip in the direction of the arrow. Repeat this for the other five clips Pull down the fuel rail so that it hangs from the hoses. R Take the fuel pump (FP) and fuel line from the kit. Insert the fuel line up at the front edge on the right-hand side of the fuel tank 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 R Pull up the fuel line so that the fuel pump (FP) is positioned approximately as illustrated. Page 9 of 19

10 20 Remove the brake pipe (1) from the clamp Take the fuel pump (FP) and bracket. Position the bracket on top of the bracket for the fuel tank mounting, opposite the small holes for the rivets Take two metal rivets (2) from the kit. Rivet the fuel pump (FP) bracket at the bracket for the fuel tank mounting. R Take the double clamp (1) from the kit. Secure the two fuel lines from the fuel pump (FP) to each other, opposite the two blue markings on the fuel lines Press the brake pipe back into the clamp Tighten the four screws holding the fuel tank. Also tighten the screw for the fuel filter if slackened off. Tighten the screws. Tighten to 24 Nm (18 lbf.ft) R 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). 22 Secure the fuel line in the brake pipe at point (1). Use a double clamp from the kit. R A Press the fuel hose from the recently installed fuel pump (FP) into place. 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. R Slide back the retaining clip for the rail. Press the rail against the car body. Page 10 of 19

11 23B Ensure that the rail is securely installed. R Raise the car slightly Remove the left front wheel Raise the car a little more Drill out the five rivets (1) in the edge of the front left wheel housing. Use a 5.5 mm (7/32 ) diameter drill bit. D Remove the two nuts (1) in the left wheel arch lining (2) Bend the wheel arch lining out of the way. D Applies only to models with an air baffle Remove the screw (1) from the left-hand air baffle (2) for the front brake Remove the left-hand air baffle by pulling it backwards (the air baffle will not be reused). Remove the right-hand air baffle in the same way. D Page 11 of 19

12 27 Remove the air baffle (2). First remove the screws (1). Press up the catches (5). Pull the air baffle downwards and backwards Remove the splash guard (4) by slackening off the screws (3) Install a hose on the engine coolant drain nipple Open the drain nipple. Drain off the coolant. D Pull off and push the pipe elbow to one side so that the fuel pipe can be positioned. R Remove the power steering pipes and the plastic hose from their clips to make installing the fuel pipe easier. The rubber coated clamp on the upper side of the front edge of the sub-frame may need to be removed in order to push the upper power steering pipe to one side. R A Install the fuel pipe using the four pre-installed clips (1) (from the kit) on the subframe. Insert the fuel pipe between the disconnected pipes and the sub-frame. Press the fuel pipe into place. Use the clips in the front edge of the sub-frame and in the bottom in the clips (2) that secured the plastic hose. On older car models, there are two free clips for the fuel line below the existing pipes on the inside on the sub-frame. Due to the limited space, the fuel pipe needs to be worked slightly to position it correctly. R Reinstall the power steering pipes. Press the plastic hose into place on the outside of the fuel pipe. On older models, the plastic hose is reinstalled in its clips. Reinstall the rubber coated clamp if this has been removed Page 12 of 19

13 30B Check that the fuel pipe does not catch on the sub-frame. Ensure that the fuel pipe does not rub against pipes or screw heads for the suspension. R Reinstall the pipe elbow Install the jack (1) under the front edge of the sub-frame Take the weight off the sub-frame Remove the screw (2) and the washer (3) from the front left mounting on the sub-frame. M Install the heater (1) on the bracket (2.) Use the screws (3) from the kit. Tighten the screws. R Position the heater for installation Take a small hose clamp for the fuel line from the kit. Install the hose clamp on the fuel hose (1) from the fuel pipe on the sub-frame Press the fuel line into place on the fuel pump (FP) inlet (2). Tighten. R Page 13 of 19

14 34 Position the bracket (1) from the kit on the screw (2) protruding into the wheel arch Take a nut from the kit. Finger tighten Install the heater and the bracket (3) in the left front mounting on the sub-frame. Use the screw (4) from the kit. Finger tighten D Turn the bracket (1) so that the hole is aligned with the screw underneath the hole in the bottom of the bracket (5) Secure both the brackets using the screw and nut from the kit. Finger tighten Check that the heater does not catch on any surrounding components Tighten the heater to the sub-frame and the brackets Tighten the screw (4). Tighten to 105 Nm (78 lbf.ft). Angle-tighten 120 or MAX 280 Nm (206 lbf.ft.) Remove the protective cover from the pre-routed connector (6). Press in the catches on the top of the connector to release the cover Connect the cable from the heater to the connector Remove the jack. 35 Take the joint cover and the short fuel line from the kit. Install the cover on the pipe. R Insert the end of the fuel line which is bent in two places, under the power steering and the anti-roll bar, on top of the rear right corner on the sub-frame. R Page 14 of 19

15 37 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 so far in that both pipes lie opposite each other. This is to prevent the build up of air bubbles Squeeze the hose clamp together. R A 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 38B R Take a hose clamp from the kit. Thread the hose clamp onto the previously routed fuel line to the fuel pump (FP) Connect the fuel line to the short fuel pipe. Slide the pipe into the fuel line. Slide the pipe so far in that both pipes lie opposite each other. This is to prevent the build up of air bubbles Ensure that the fuel line is routed correctly. Ensure that the fuel line does not obstruct the plastic hose or rub against the sub-frame or other components Squeeze the hose clamp together. Note! R Fuel lines and fuel pipes must be at least 15 mm (19/32 ) from brake pipes. 39 Take a tie strap from the kit. Clamp the fuel pipe at the plastic hose. R Page 15 of 19

16 40 Take a double clamp from the kit. Clamp the fuel line for the parking heater at the ordinary fuel line. R Pull off the protective cover in front of the fuse holder. Place the protective cover to one side. It is held by three lower clips. Pull off one clip at a time. M Remove the three screws for the intake manifold in the front cover plate. M Remove the three screws holding the air cleaner at the mountings on the gearbox. M Page 16 of 19

17 44 Remove the connector (1) from the intake manifold Remove the vacuum valve (2) with the hoses (2) from the mountings in the air cleaner Remove the hose clamp (3) on the intake manifold. M Pull off the intake manifold from the corresponding pipe under the front cover plate. Move the intake manifold to the right Grasp the air cleaner and carefully twist off from the intake manifold. Place it to one side. Note! M If the hose is plastic, the hose joint will need to be carefully heated to release the hose. Use a hot-air gun. 46 Release the quick-release connector on the left heater hose (1) for the passenger compartment heater. Press in the circlip on the quick-release connector opposite the two arrow heads. At the same time, turn the circlip in the direction indicated by the arrow. Turn the quick-release connector slightly and pull it out Detach the heater hose (2) on the left-hand side of the cylinder head Remove the thick engine coolant hose at the cylinder head to facilitate access M Remove the heater hose. The heater hose will not be reused. 47 Take the heater hoses from the kit and thread them along the front edge of the gearbox and out to the left front mounting of the sub-frame Connect the shorter of the heater hoses to the connector (1) on the left-hand side of the cylinder top. Secure using a new hose clamp from the kit M Pull the longer of the heater hoses along the inside of the left-hand front member and over the gearbox. Continue to pull the hose behind the intake manifold and up to the turbocharger (TC). Then pull the hose in the same direction as the old heater hose. Connect it where the old heater hose was removed Reinstall the thick radiator hose at the top of the cylinder head (if disconnected). Page 17 of 19

18 48 Take the rubber coated clamp and M8*16 screw from the kit. Secure the heater hose up from the cowl panel. Tighten the clamp at the existing hole in the gearbox end above the drive shaft. M Connection and finishing work Connect the two heater hoses (1) to the heater with the hose clamps from the kit. Tighten. R Connection and finishing work Tighten the drain nipple on the radiator. Remove the hose Reinstall the engine splash guard. Tighten to 25 Nm (18 lbf.ft.) Reinstall the centre air baffle. First the centre one and then reinstall the righthand one Fold the wheel arch lining back into position. Secure the wheel arch lining using the two nuts Rivet the front edge of the wheel arch lining. Use the pop rivets from the kit Lower the car slightly. Reinstall the wheel. Tighten to 140 Nm (103 lbf.ft.). Page 18 of 19

19 51 Connection and finishing work Open the fuse holder cover in the engine compartment. Install a 25A fuse in position 1 Reinstall the cover. M Connection and finishing work Lower the car completely Fill with coolant. Reinstall the expansion tank cap Reinstall the air cleaner and connections Reinstall the intake manifold for the front cover plate Reinstall the protective cover in front of the fuse holder Start the engine. Bleed the radiator system Program the software. See the service information in VIDA Test the heater function according to separate instructions. Page 19 of 19