This is based on the Volvo installation instructions, available here. I wil reference the steps in this document with my additional notes and pictures.
First of all, my tow bar came very poorly packed. In the end it was fine, be the only packing materiel was a squished cardboard box. There were loose pieces in the box, but nothing was missing.
Step 0: Clean your car, especially the wheel wells. I pressure washed the wheel wells last weekend, but after a rainy week, they were a mess. I really should have stopped and washed the car.
Step 5: When you open the rear hatch, If you have a TV transceiver, make sure the right rear door is also unlocked, or just leave it open.
Step 11: Use a tool to gently apply pressure at the bottom of the wheel well arch. You can see the tabs in the second picture which can be pushed in with your finger. First one is the hardest.
Steps 12 & 13 are pretty easy, just be gentle It may help for step 12 to use some needle nose pliers to squeeze the cones from the backside.
Step 14: First one is the hardest. Again be gentle.
Step 15 looks like this:
Step 18: Plug looks like this once disconnected.
Step 20: I used a moving blanket, but make sure you don’t scratch the paint on the bumper. It will now look like this:
Step 21: You won’t re-use these nuts. Kit comes with new ones.
Step 22: Old bumper is aluminum and surprisingly light.
Step 23: Don’t do this by yourself. It’s heavy.
Step 25: My 2016 had the weld nut so skipped 27-29.
Step 26: 50 Nm isn’t that much. At the lower range of my 1/2″ torque wrench.
Here’s what it looks like now
Step 30: IMPORTANT. There are two alternatives. I had the first so didn’t need to cut heat shield and could skip to step 35.
Step 35: Picture is confusing. Mine looks like this:
Step 36: Mine came with foam already attached.
Step 39: IMPORTANT This is only for vehicles with TV transceiver (?). I didn’t notice the text and did a lot of un necessary work to remove large side panel. It wasn’t too bad, and made some steps easier, but if you don’t have a TV transceiver, skip all the way to step 58
Step 47: This is the backside of the piece you just removed. If you don’t have a TV transceiver, you shouldn’t be doing this.
Step 60: I couldn’t see an easy way to fold the insulation, so I left it.
Step 64: Because I didn’t move insulation, I had to very carefully feel edges of grommet to make sure they had seated correctly.
Step 65:
Step 66: Wasn’t obvious to me until later that box will be completely hidden inside large green (in diagram) plastic piece.
Step 67: I installed cable tie later when I was sure of positioning. Suggest you do too. Which wires go where isn’t too obvious. No need to tuck them in. Just move on to hooking up ground.
Step 69: This piece was loose in the bottom of my box so I used it. No idea why they say “Remove the marked part or The part is not to be reused”
Step 76: This was easier for me, because I removed the entire panel, but you’re just fishing the longest wire up to where the button will go.
Step 81: Confusing view. Imagine the side of the car is gone, and your spare tire is on the other side of the green (in diagram) piece. Brown part is fuse box cover.
Step 85:
Step 87: These are the two pre-wired connectors. Remove the foam
Step 89: The want the control box about as far forward as it will go. A little bit of a tight squeeze getting it in under there. Be careful.
Step 90: Plugs installed, box ready to be mounted.
Step 92: My car already had both fuses. Now I have spares, where to keep them?
Step 93: My car is an R-design, so the second one in Alternative 1.
Step 95: These lines were pretty faint, and it was very dirty. Washed inside of bumper and could see them a little better.
Step 96: The little bump out at the top left will be the most visible when done, so be extra careful.
Step 97: Tape the back side.
Step 98: This was the scariest part. I used my oscillating tool. Perhaps not the best tool for the job, but I’m very happy with the result. If you use a dremel, practice on a sacrificial bit. No need to remove the part in one piece.
Step 99: A rounded file worked well for deburring.
Step 101: Get help from a friend or spouse.
Step 107: This requires the dealer. I’m headed there tomorrow. Total time was about three hours, but if I had to do another, I could probably get it done in less than 2 hours.