Fuel driven heater, bi-fuel

• Fold the right-hand rear seat cushion forward.

• Fold the right-hand rear backrest forward.

• Remove the right-hand side cushion. First pull the top edge (1) towards you. Then lift the side cushion upwards (2).

• Remove the rear seat cushion (1) by pulling it up at the front and then forwards.

• Fold the right-hand rear backrest forwards
• Remove the seat belt from the guide (1).

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.

Illustration A

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 top of the side cushion. Then pull upwards.

Illustration B

Applies to the S80

• 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
• Place the cushion to one side
• Fold the backrest forward.

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).

• 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.

• 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 4 mm (5/32”) diameter drill bit.

Примечание: Use a compressed air power drill with a greased bit.

• Remove the protective panel on the petrol tank. First remove the four nuts on the underside and the two screws in the rear end.

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

• 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).

• 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.

• Remove the right-hand rear wheel. This facilitates the routing of the fuel line
• Route the fuel line and cable harness (1) at the rear edge of the fuel tank. Route them under the existing fuel line. Ensure that the cable harness is at the bottom to avoid contact with the fuel lines. Apply a double clamp between the fuel lines. Route the fuel line and cable harness forwards along the right-hand side of the fuel tank, and allow them to hang down.

• 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 and the pipe.

• Cut off the three clips holding the fuel line, plastic line and power cable in place.

• Take two screws and nuts from the kit. Take the fuel pump (FP), fuel line and pipe from the kit. Install them in the holes where the clips were previously removed.

• Connect the wiring and the quick-release connector for the fuel line to the fuel pump (FP).

Illustration A

• Take four double clamps from the kit. Clamp the fuel lines from the pump to the existing fuel line (1, 2). Clamp at the front connection on the pump, the strap for the petrol tank (2) and the wiring for the pump (3), as illustrated. The small petrol tank is not present in cars with the LPG system. The fuel line that was clamped to the strap for the petrol tank, as illustrated, is clamped instead at the regular fuel line in the same area. Ensure that the wiring comes from the fuel lines. Ensure that the fuel line to the pump is positioned inside the fuel tank frame, from the point indicated by the arrow and forwards.

Примечание: Check that the fuel pump (FP) tilts down 15-35° at the rear edge. This is to prevent impaired suction. Adjust the clamping of the fuel lines and the mounting of the rubber bracket for the pump in the metal bracket if necessary.

Осторожно: Check that no components rub against the petrol tank.

Illustration B

• Clamp the cable that was previously disconnected in order to install the pump bracket. Use the tie straps and the clips from the kit.

• Use a knife to cut out a corner at the front and rear edges on the left-hand side of the rail for the fuel lines. This makes room for the fuel pipe that will be routed through there. Adjust the cut out tab so that the fuel line is not tight against the rail.

• Disconnect the plastic tube from the rail for the fuel lines
• Use a 6.5 mm (1.4”) diameter drill bit. Drill three holes along the rail. Drill approximately as indicated by the arrows. Drill the holes 15 mm (19/32”) from the edge. Ensure that the holes are drilled where the surface is flat on the inside of the rail. This facilitates secure mounting of the clips
• Take three tie straps from the kit. Press the tie straps into the drilled holes.

Illustration A

• Place the fuel pipe in the tie straps. Tighten the tie straps a little, but do not tightly secure the fuel pipe yet.

Illustration B

• Adjust the position of the pipe in the rail so that the black plastic protection on the hose/pipe is positioned as illustrated
• Tighten the tie straps securely
• Press the rail into place on the body. Ensure that it is properly secured
• Take the spacer collar, tie straps and two double clamps from the kit. Press the spacer collar (1) into place on the fuel line. Press the two double clamps (2) onto the two fuel lines in front of the petrol tank
• Clamp the plastic hose and the two fuel lines to each other. Use tie straps (3).

Applies to the V70

• Cut the fuel line to 260 mm (10 1/4”).

Applies to the S60

• Cut the fuel line to 220 mm (8 11/16”).

Applies to the V70

• Cut the fuel line insert pipe to 215 mm (8 7/16”).

Applies to the S60

• Cut the fuel line insert pipe to 175 mm (6 7/8”).

• Insert the fuel line insert pipe as far as possible into the hose.

• 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.

• Remove the two nuts (1) in the left wheel arch lining (2)
• Bend the wheel arch lining out of the way.

Applies to cars with air baffles

• 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.

• 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.

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

• 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.

• 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. 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 limited space, the fuel pipe needs to be worked slightly in order to position it.

• 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. Ensure that the fuel pipe does not rub against pipes or screw heads for the suspension.

• 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.

• Install the heater (1) on the bracket (2.) Use the screws (3) from the kit. Tighten the screws.

• Position the heater for installation
• Take a small hose clamp (from the kit) for the fuel line. Install the clamp on the fuel line (1) from the fuel pipe on the sub-frame
• Press the fuel line on the inlet (2) on the fuel pump (FP). Tighten.

• 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 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.

• Take the joint cover and the short fuel line from the kit. Install the cover on the pipe.

• 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.

• 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.

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. 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.

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

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

• Take a double clamp from the kit. Clamp the fuel line for the heater in place at the normal fuel line.

• Remove the intake manifold for the air cleaner
• Remove the hose clamp on the rubber hose from the air cleaner
• Remove the hose from the intake manifold for the engine
• Pull the air cleaner off the mounting in the front member
• Push the air cleaner to one side so that the gearbox is exposed
• Cover the inlet for the engine intake manifold.

• Disconnect the quick-release connector on the left heating hose (1) for the passenger compartment heater. Press in the circlip on the quick-release connector opposite the two arrows. At the same time turn the circlip in the direction of the arrows. Turn the quick-release connector a little and pull it out
• Disconnect the heater hose (2) on the left-hand side of the cylinder head.

Applies to cars manufactured after week 26, 2002

• Place the heater hose to one side. It will not be reused.

• Route the heater hose previously routed from the cowl and the cylinder head. Remove the hose clamp on the hose to the gas regulator. Pull off the hose
• Put the heater hose with the angled connector and T-connector to one side. These will not be reused.

• Take the guards from the kit. Press the protection on the front and rear edge of the bracket for the gas regulator to avoid rubbing.

• Take the hose unit from the kit. Cut the two hoses from each other.

• Cut off the hose and the angled connector 80 mm (3 1/8”) from the lower edge of the clamped connection as illustrated. Both components will be reused.

• Cut off the remaining straight section of the hose to the angled connection 100 mm (4”). The short piece of hose will not be reused.

• Pull the guard down on the hose to the cowl, to the position as illustrated
• Take a tie strap from the kit. Tighten the guard to the hose.

• Pull the long guard on the hose to the cylinder head, up against the short guard nearest the short bend. Ensure that the guards overlap
• Take a tie strap from the kit. Tighten the guard to the hose.

Illustration A

• Take the cut hose and position the cut end (on cars built after week 226, the hose end with the quick-release connector) at the cowl, next to the other hose. Then route the hose forwards at an angle over the gearbox, below the bracket for the gas regulator. Continue to route the hose up to and along the left-hand side member, under the existing vacuum hose and down at the front left-hand corner of the sub-frame
• Connect the quick-release connector to the hose connector in the cowl panel (applies to cars manufactured after week 26, 2002)
• Take the remaining hose with the angled end. Route the angled end under the thick coolant hose to the connection on the cylinder head. If necessary, remove the large coolant hose to gain access
• Press the hose into place in the connection. Tighten the hose using the existing hose clamp
• Route the other end of the hose down below and around the existing cable harness. Route the hose over the vacuum hose and down to the other routed hose
• Clamp the hoses using the appropriate clamps from the kit
• Ensure that the vacuum hose is in its original position.

Illustration B

• Illustration B displays the left-hand hose clamped with a double clamp in the third brake pipe from the front, underneath the ABS unit, and with the clips in the holes at the bracket for the ABS unit
• Install a guard around the gas line as illustrated. Install the guard using a tie strap from the kit.

Осторожно: Secure the hose unit so that it does not rub against any sharp edges or moving parts in the engine compartment.

• Assemble the cut angled connection, T-connector and the hose clamp from the kit
• Lubricate the inside of the end of the hose to facilitate installing the T-connector. Use a soap solution
• Turn the T-connector slightly in relation to the angled connection so that it corresponds to the other T-connector on the other heater hose in the cowl. Do not tighten the hose clamp yet.

• Take a large and a small hose clamp from the kit
• Route the heater hose that was positioned at the cowl. Install the large hose clamp on the heater hose. Position the hose clamp so that it does not rub against the other heater hose at the cowl
• Install the angled connector and the T - connector. Do not tighten the hose clamp yet
• Install the small hose clamp on the hose to the gas regulator. Install the hose on the T-connector. Do not tighten the hose clamp yet
• Press the angled connector into the cowl
• Adjust the position of the hoses, hose clamps and T-connector to prevent trapping and rubbing
• Tighten the hose clamps.

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

• Take the protective panel for the gas and fuel tank. Cut / drill a cut-out for the fuel hose to the heater in the front left-hand corner of the protective plate
• Smooth off the edges on the inside and outside of the cut-out. This prevents the fuel hose from being worn through
• Reinstall the protective panel for the petrol tank.

• 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 and then reinstall the right-hand 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 using the pop rivets from the kit
• Lower the car slightly. Reinstall the wheels. Tighten to 140 Nm (103 lbf.ft.).

• Open the fuse holder cover in the engine compartment. Install a 25A fuse in position 1
• Reinstall the cover.

• Lower the car completely
• Fill with coolant. Reinstall the expansion tank cap
• Reinstall the air cleaner, pipes and connectors
• Start the engine. Bleed the radiator system
• Program the software. See the service information in VIDA
• Test the heater function according to separate instructions.