Installing additional insulation

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2006 Volvo S80, 2005 Volvo S80, 2004 Volvo S80, 2003 Volvo S80, and 2002 Volvo S80. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Insulation Positioned At Fuel Heater Connection To Fuel Pipe

Courtesy of VOLVO CARS OF NORTH AMERICA.

Carefully pull down the fuel pipe at the auxiliary heater.

Position the insulation. Start at the fuel heater connection to the fuel pipe.

NOTE: Make sure that insulation seams lie back toward the subframe.

Do not overtighten the tie straps around the insulation.

Secure the insulation using tie straps.

Cut off any excess from the tie straps.

Fig 2: Identifying Insulation Positioned To Wrap Fuel Pipe

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 3: Identifying Insulation Wrapped and Secured With Tie Straps

Courtesy of VOLVO CARS OF NORTH AMERICA.

Secure the insulation using tie straps.

NOTE: Use several tie straps in spots with sharp curves to ensure that the insulation is properly secured.

Cut off any excess from the tie straps.

Fig 4: Identifying Tie Straps Inserted In Clips In Subframe

Courtesy of VOLVO CARS OF NORTH AMERICA.

Insert tie straps in the two clips in the subframe by the auxiliary heater but do not tighten them yet.

Fig 5: Identifying Insulation Secured With Tie Straps

Courtesy of VOLVO CARS OF NORTH AMERICA.

Secure the insulation using tie straps.

Cut off any excess from the tie straps.

Fig 6: Identifying Insulation Secured With Tie Straps

Courtesy of VOLVO CARS OF NORTH AMERICA.

Secure the insulation using tie straps.

NOTE: For easier access to the fuel pipe, move aside the AC hose on variants in which it is in the way.

Cut off any excess from the tie straps.

Fig 7: Identifying Tie Straps Inserted In Clips In Right Part Of Subframe

Courtesy of VOLVO CARS OF NORTH AMERICA.

Insert tie straps in the two clips in the right part of the subframe but do not tighten them yet.

Secure the insulation using tie straps.

Cut off any excess from the tie straps.

Fig 8: Identifying Fuel Pipe Insulation

Courtesy of VOLVO CARS OF NORTH AMERICA.

Continue fitting insulation over the fuel pipe up and over the subframe.

Fig 9: Identifying Fuel Pipe Clipped To Subframe

Courtesy of VOLVO CARS OF NORTH AMERICA.

Press the fuel pipe into the clip on the top of the subframe.

Secure the insulation using tie straps.

NOTE: The fuel pipe is partly accessible from the right wheel housing when the fender liner is moved up.

Cut off any excess from the tie straps.

Fig 10: Identifying Insulation Secured With Tie Straps

Courtesy of VOLVO CARS OF NORTH AMERICA.

Continue fitting insulation over the fuel pipe.

Secure the insulation using tie straps.

NOTE: It is extremely important to secure insulation where the fuel pipe swings down and goes back.

Cut off any excess from the tie straps.

Fig 11: Identifying Fuel Pipe Pressed To Clips

Courtesy of VOLVO CARS OF NORTH AMERICA.

Press the fuel pipe into the clips.

Fit a tie strap on each side of the clips with the opening inward. This ensures that the clip holds the fuel pips in place.

Fig 12: Identifying Insulation Secured With Tie Straps

Courtesy of VOLVO CARS OF NORTH AMERICA.

Secure the insulation using tie straps.

Cut off any excess from the tie straps.

Cut off any excess insulation hose at the fuel hose.

Press the fuel pipe into the clips.

Reinstall the pipe in its original position against the front edge of the subframe.

Tighten the remaining tie straps in the clips (x4).