Part 2

Styling pack, skid plate and exhaust system

Applies to all models




- Remove the rubber mountings from the mounting hooks in the bodywork. The rubber mountings will not be reused. New ones are in the kit.

Applies to cars without a tow hitch





Note! Two mechanics are needed for this step.

- Remove the screws in the bracket underneath the left side member.
- Pull out the exhaust pipe at the front joint and place to one side.
- The rubber mounting with bracket will not be reused. New ones are in the kits. The screws will be reused.
- Place the exhaust system to one side. New system in the kit.
- Remove the gasket at the front joint and discard it. New nuts and new gasket will be used at installation.





- Remove the two screws in the bracket for the towing eyelet. The screws will be reused. Place the towing eyelet to one side. New one found in the kit.





- Take the left-hand mounting bracket from mounting kit exhaust system for cars without tow hitch and rubber mounting part no. 9186408from installation kit exhaust system 8, 6 or 5 cyl diesel and install the rubber mounting on it.
- Install the unit under the side member and install existing screws. Do not tighten hard yet.





- Take the new towing eyelet from installation kit exhaust system for cars without tow hitch and rubber mounting part no. 9186408 from installation kit exhaust system 8, 6 or 5 cyl diesel and install the rubber mounting again on it.
- Install the unit under the side member and install existing screws. Do not tighten hard yet.

Applies to cars with a tow hitch





Note! Two mechanics are needed for this step.

- Unhook the silencer's rubber mounting from the hook on the tow bar's side panel.
- Pull out the exhaust pipe at the front joint and place to one side.
- The rubber mounting will not be reused. New mounting in the kit.
- Place the exhaust system to one side. New system in the kit.
- Remove the gasket at the front joint and discard it. New nuts and gasket will be used.





- Fold the silencer heat shield to one side to access the lower nuts for the tow bar's reinforcement plate.
- Remove the nuts and discard them. Turn the screws and reinstall.
- Repeat the operation on the other side.





- Take the mounting hooks from the kit Towbar, installation kit, XC90 R-design and install the hook on the screws. Take new nuts, install them and tighten to 50 Nm (37 lbf.ft.).
- Repeat the operation on the other side.





- Install new rubber mounting part no. 9186408 from installation kit exhaust system 8, 6 or 5 cyl diesel on the hook.
- Repeat the operation on the other side.

Applies to cars with parking assistance




- Disconnect the cable harness to the sensors from the rear section of the bumper.

Applies to all models




- Unhook the ten catches at the upper edge of the bumper.
- Release the nine hooks in the middle of the bumper, at the same time as separating the rear section and outer section of the bumper.
- Remove the rear section from the bumper cover.

Applies to cars with a tow hitch




- Take a new holder for the bumper from the kit and saw out according to the marking. Remove the shaded area.
- Smooth off the sawn edges with a fine toothed file.
- A Detachable towbar
- B Fixed towbar
- C Hitch towbar













- Take the bumper's rear section and measure the dimension as illustrated. Carefully saw off the holder on the rear section. It will not be reused.
- Smooth off the edges using a file.





- Smooth off the edges on the inside where the new holder is to be placed against.





- Take the holder from the kit and secure the rear section from the inside.


A




- Take measurements for the drilling of the three holes for the attachment of the holder.
- Secure the holder to the rear section properly and drill out the three holes through the rear section and holder.
- Remove any swarf.

B




- Image B shows dimension drawing of the location of the holes.
- Same hole position in all locations.





- Take rivets from the kit and rivet the rear section into place.





- Secure the rear section in the bumper cover. Make sure that all catches engage.
Applies to cars with parking assistance
- Ensure that the wiring for the sensors is correctly positioned.





Applies to cars with parking assistance
- Secure the cable harness for the sensors in the rear section.

Applies to all models




- Take the two rubber mountings part no. 9179238 from kit exhaust system 8 or 6 cyl, or part no. 9492157 from exhaust system 5 cyl diesel.
- Install them in the suspension hooks in the bodywork.






Note! Two mechanics are needed for this step.Ensure that the mating surfaces in the joint between the various parts in the exhaust system are clean.All clamp nuts and gaskets must be replaced with new ones.

- Take the long part of the new exhaust system and install.





- Hook the rubber mounting onto the exhaust system brackets.

Applies to cars with 8-cylinder engine




- Tighten the nuts to 25 Nm (18.5 lbf.ft).

Applies to cars with 6-cylinder engine




- Tighten the nuts to 25 Nm (18.5 lbf.ft).

Applies to cars with 6 and 8 cylinder engines




- Torque tighten the screws to 25 Nm (18.5 lbf.ft.).

Applies to cars with 5-cylinder diesel engine




- Tighten the nuts to 25 Nm (18.5 lbf.ft).





- Torque tighten the screws to 25 Nm (18.5 lbf.ft.).

Applies to all models




- Hook the rubber mounting on for the left silencer.





- Take the remaining silencer from the kit and install it on the previously installed exhaust system.
- Hook the previously installed rubber mounting onto the silencer's hook.
- Do not tighten the joint in the silencer yet.


A, B, and C




- Reinstall the bumper cover.
- Connect the connector under the rear lamp.
Applies to cars with parking assistance
- Position the connector for the sensors on the lug on the rear section.










Applies to cars with mudguards






Applies to all models













- Install the four nuts that hold the bumper to the bodywork. Tighten to 24 Nm (18 lbf.ft.).
- Reinstall the four pieces of insulation.

Applies to cars with parking assistance




- Route the connector for the cable to the sensors.
- Secure the foam rubber seal.























Applies to cars with a tow hitch




- Take the skid plate from the kit and saw out according to the markings. Remove the shaded area.

Note! Do not damage the paintwork of the bumper cover.

- Smooth off the sawn edges with a fine toothed file.
- A Detachable towbar
- B Fixed towbar
- C Hitch towbar










Applies to all models

A and B




- Secure the skid plate in the bumper cover. Make sure that all catches engage.
- Take four clips from the kit. Fold up the rear edge on the skid plate around the holder and install with the clips.









- Secure the cord for the cover to the towing eyelet mounting in the lower right-hand corner of the hole in the skid plate. Secure the cover in the skid plate.


A




- Align the silencer's end pipes in the cut-out in the skid plate so that they are centered in the cut-out on both sides.
Applies to cars without a tow hitch
- Tighten the screws in the brackets for the mountings for the rear silencers. Torque tighten to 80 Nm (59 lbf.ft.).

B




- Tighten the nut at the joint for the right-hand silencer. Torque tighten to 37 Nm (50 lbf.ft.).