Volvo 912-D User manual

Instruction No Version Part. No.
8698855 1.0
Fuel driven heater 912 - D
R8703687
Instruction No Version Part. No.
8698855 1.0
Fuel driven heater 912 - D
R8703687
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Fuel driven heater 912 - D - 8698855 - V1.0
Side 1 / 24

Equipment
A0000162 A0000163 A0801450
M8703813
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Fuel driven heater 912 - D - 8698855 - V1.0
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M8703808
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Fuel driven heater 912 - D - 8698855 - V1.0
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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.
Applies to the V70 XC
1
M8503342
Applies to the V70 XC
Fold the centre seat cushion (1) forwards. Fold the centre
backrest (2) forwards by pulling the lever (3) towards you.
2
Remove the centre backrest. First pull the handle at the top of the
reverse of the backrest. Then pull the backrest upwards.
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
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M8503340
Applies to the V70 and V70 XC
3
M8503773
Applies to the V70 and V70 XC
Fold the right -hand rear seat cushion forward.
4
M8503886
Fold the right -hand rear backrest forward.
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5
A8502769
Remove the right -hand side cushion. First pull the top edge (1)
towards you. Then lift the side cushion upwards (2).
Applies to S60 and S80
6
D8503879
Applies to S60 and S80
Remove the rear seat cushion (1) by pulling it up at the front and
then forwards.
7
Applies to the S80
Fold the right rear backrest forward
Remove the seat belt from the guide (1) on the right-hand side
cushion
Insert a hand down the side of the lower section of the right side
cushion
Release the catches. At the same time lift the side cushion
Put the cushion to one side.
Installation instructions, accessories
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D8502762
8
M8503548
Applies to the S60
Fold the right rear backrest forward
Remove the seat belt from the guide (1) on the right side cushion.
9
M8503549
Applies to the 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.
10 Applies to the 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 upper edge of the
side cushion. Then pull upwards.
Installation instructions, accessories
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M8503367
Applies to all models
11
M8802583
Applies to 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).
12
M8503338
Applies to the right-hand side
Disconnect the connector (1) and the screw (2) on the right
backrest
Lift up the mounting (3) and pull out the backrest by twisting it
backwards and forwards to remove the pin from the mounting in
the left backrest
Remove the right backrest.
13
Push the insulation panel to one side so that the cover (1) is
accessible
Remove the nuts (2) and the cover
Installation instructions, accessories
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D2302195
Drill out the connection (3) in the fuel tank unit (4). Use a 4 mm
(5/32”) diameter drill bit.
Note!
Use a compressed air power drill with a greased bit.
14A
R2501320
14B
R2501321
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 lowers slightly. This allows the suction pipe for
the fuel tank to be installed.
15
Insert the pipe (1) (from the kit) into the connection (2). Press the
pipe down until it is in contact with the connection
Installation instructions, accessories
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M2302970
Take the fuel line with the power cable from the kit. Apply tape
on 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 cable
end.)
Insert the whole cable assembly (3) between the floor and the
fuel tank out to the right.
16
M2302961
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).
17
Position the wiring in the rubber grommet in the cover. Reinstall
the cover. Tighten the cover using the four nuts.
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.
18
Route the fuel hose with the cable harness (1) at the rear edge
of the fuel tank. Route along the right-hand side of the fuel tank
Installation instructions, accessories
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D2302957
and allow the hose to hang.
19
R2303046
Detach the fuel rail (1) by inserting 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 clips.
There are six clips to disconnect
Pull down the fuel rail so that it hangs from the hoses.
20
D2302958
Take the fuel pump (FP) and cable from the kit. Insert the cable
up at the front edge on the right-hand side of the fuel tank
Route the cable so that is next to the existing cable in the cut-out
on top of the fuel tank. Then position the cable 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.
Installation instructions, accessories
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21
D2302959
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.
22
D2302960
Take the double clamp 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 securing the fuel tank. Tighten the
screws. Tighten 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).
23
Secure the fuel line in the brake pipe at point (1) using a double
clamp from the kit.
Installation instructions, accessories
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D2302977
24A
R2303048
24B
R2303055
Press the fuel hose from the recently installed fuel pump into
place at the bottom of the rail and forwards, in the cut-out further
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.
25
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.
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
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D8600370
26
D8600371
Remove the two nuts (1) in the left wheel arch lining (2)
Bend the wheel arch lining out of the way.
27
D2000257
Raise the car
Remove the screw (1) from the left air baffle (2) for the front
brake
Remove the left -hand air baffle by pulling it backwards. Place the
air baffle to one side. It will not be reused because it obstructs
the heater
Remove the right air baffle in the same way.
Note!
It will be reinstalled later
28
Remove the screws (1). Remove the air baffle (2) by pressing in
the catches (3)
Remove the screws (4). Remove the engine splash guard (5)
Thread a hose onto the engine coolant drain nipple
Open the drain nipple. Drain off the coolant.
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M2000351
29
R2303064
Pull off and push the pipe elbow to one side so that the fuel pipe
can be positioned.
30
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.
31A
Install the fuel pipe using the four pre-installed clips (1) (from the
kit) on the sub-frame. Insert the fuel pipe between the
disconnected pipes and the sub-frame. Press the fuel pipe into
place using 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 limited
space, the fuel pipe needs to be worked slightly in order to
position it.
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R2303047
31B
R2303066
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
Check that the fuel pipe does not catch on the sub- frame. Check
that the fuel pipe does not rub against pipes or screw heads for
the suspension.
32
M6400527
Reinstall the pipe elbow
Install the mobile 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.
33
Install the heater (1) on the bracket (2.) Use the screws (3) from
the kit. Tighten the screws.
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R8703683
34
R8703684
Position the heater for installation
Take a small hose clamp (from the kit) for the fuel line. Install the
clamp on the fuel hose (1) from the fuel pipe on the sub-frame
Press the fuel line on the inlet (2) on the fuel pump (FP). Tighten.
35
D8703767
Position the bracket (1) (from the kit) on the screw (2) protruding
in 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
Turn the bracket (1) so that its hole is aligned with the screw
underneath the hole in the bottom of the bracket (5)
Secure both 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 mobile jack.
Installation instructions, accessories
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36
R2303052
Take the join cover and the short fuel line from the kit. Install the
cover on the pipe.
37
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.
38
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 far that the two pipes are in contact
with each other. This prevents air pockets from forming
Squeeze the hose clamp together.
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R2303068
39A
R2303069
39B
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 the hose clamp onto the
fuel line up to the fuel pump (FP) that was routed previously
Connect the fuel line to the short fuel pipe. 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
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!
The fuel lines and fuel pipes must be at least 15 mm (19/32 ”)
from the brake pipe.
40
Take a tie strap from the kit and clamp the fuel pipe at the plastic
hose.
Installation instructions, accessories
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R2303071
41
R2303072
Take a double clamp from the kit. Clamp the fuel line for the
heater into place at the normal fuel line.
42
M2102175
Remove:
the four screws holding the engine cover
the engine cover. Place the cover to one side.
43
Remove the intake manifold (1) from between the radiator and
the air cleaner (ACL)
Remove the hose clamp (2) on the hose between the air cleaner
(ACL) and the intake manifold for the turbocharger (TC)
Disconnect the connector (3) from the air cleaner (ACL)
Remove the vacuum valve (4) with the hoses from the air
cleaner (ACL). Bend out the catch from the rear edge. Pull the
vacuum valve and hoses upwards
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