Applies to the S60 and V70 (00-) Preparations

Applies to the S60 and V70 (00-) Preparations

• Remove the overrider moulding from the bumper. Pry up the moulding at one corner using a weatherstrip tool. Then pull off the entire moulding.

• Cut a hole in the overrider moulding according to the marking (1) on the reverse of the moulding. Use a utility knife or similar. Leave a safety margin when cutting. Finely adjust the size if the hole using a file.

• Reinstall the overrider moulding

• Install the protective cover (1) for the front engine block heater socket in the moulding

• Mark out the hole in the bumper cover (2) using a 29 mm (1 1/8") diameter hole saw and the centre drill bit

• Remove the protective cover. Drill out the hole using a 29 mm (1 1/8") hole saw

• Remove any swarf

• Reinstall the splash guard.

• Raise the car.

Remove:

• the screw (1) from the left air baffle (2)

• the left-hand air baffle by pulling the air baffle backwards

• the right-hand air baffle in the same way.

Remove:

• the air baffle (2). First slacken off the screws (1). Press up the catches (5). Move the air baffle downwards and backwards

• the engine cover (4) by slackening off the screws (3).

Installing the front engine block heater socket

• Route the cable for the front engine block heater socket through the protective cover (1) and the bumper cover (2)

• Install the plastic nut (3) from the kit on the front engine block heater socket. Tighten the plastic nut. The cover must be horizontal and is opened forwards.

• Route the wiring down along the left-hand side of the side member.

Applies to the XC90 Preparations

Applies to the XC90 Preparations

• Remove the left-hand headlamp by pulling up the two cotter pins and then carefully pulling the headlamp forwards.

• Carefully pry up the catch on the connector for the headlamp using a screwdriver

• Pull up the catch completely. Disconnect the connector. Place the headlamp to one side.

• Carefully pry up the left-hand grille on the bumper up using a weatherstrip tool. Remove the grille.

• Measure for drilling out the hole for the front engine block heater socket as illustrated

• Pre-drill the hole using a 3 mm (1/8”) diameter drill bit

• Drill out the hole. Use a 29 mm (1 1/8”) diameter hole saw

• Remove any swarf.

• Cut the tabs (1) using a utility knife so that they are the same height. This ensures a flat surface against which the plastic nut for the front engine block heater socket can be tightened.

• Make a cut out for the connector for the front engine block heater socket in the second hole from the left in the left-hand bumper grille

• Smooth off the edges

• Press the grille into the bumper.

Installing the front engine block heater socket

Illustration A

• Take the front engine block heater socket, protective cover and plastic nut from the kit

• Install the protective cover on the front engine block heater socket connector. Turn the connector so that the cover opens towards the left-hand side of the car as illustrated.

Illustration B

• Install the plastic nut

• Tighten the plastic nut well. Connect the cable to the front engine block heater socket to use as a counterhold when tightening the plastic nut

• Route the wiring down along the left-hand side of the side member.

• Remove the engine splash guard (1) by first removing the screws (2).

• Remove the three screws (1) holding the stay to the exhaust pipe at the cylinder block and exhaust pipe

• Remove the stay.

Applies to all models Installing the engine block heater

Applies to all models Installing the engine block heater

• Drill a hole at the front edge/lower edge of the side member using a 4 mm (5/32") diameter drill bit

• Rust-proof and secure the ground lead using the supplied 4.8 mm (3/16") diameter flanged screw and toothed washer (under the screw head).

  
  

  Note! Connect the ground lead to the side member, not to the sub-frame.

  
  

• Secure the ground lead excess using a tie strap.

• Apply heat conducting paste, (P/N 9499205) to the surfaces (1) of the heater body which are in contact with the cylinder block.

• Grease the O-ring on the connector for the heater joint cable. Use low temperature grease, (P/N 1161417-9).

Applies to the S60 and V70 (00-)

• Clean the area where the heater will be positioned. This ensures optimal heat conduction to the cylinder block. Also clean the internal thread

• Connect the supplied joint cable to the heater. Install the locking sleeve (from the kit) over the cable splice on the cable

• Thread the radiated heat protection over the cable for the heater

• Install the heater on the cylinder block, as illustrated

• Install the screw with the tensioner and spacer sleeve from the kit. Tighten the heater. Tighten to 16 Nm (12 lbf. ft).

Applies to the S60 and V70 (00-)

• Pull the radiated heat shield all the way up to the engine block heater so that the cable splice and the plastic surround are completely covered.

  
  

  Note! It is important that the radiated heat shield covers the entire joint cable to the engine.

  
  

• Secure the radiated heat shield around the cable to the engine block heater. Use a grey heat resistant tie strap in the lower edge of the radiant heat shield.

Applies to the XC90

• Clean the area where the heater will be positioned. This ensures optimal heat conduction to the cylinder block. Also clean the internal thread

• Insert the short joint cable up between the bevel gear and the cylinder block, in front of the oil pipe for the turbo

• Press the engine block heater onto the joint cable.

Applies to the XC90

• Install the engine block heater in the cylinder block by pressing the engine block heater cable joint down as far as possible between the bevel gear and the cylinder block. The top of the engine block heater must not be in contact with the engine coolant pipe which runs along the cylinder block. Insert the engine block heater into the cylinder block.

Applies to the XC90

• Press a locking sleeve (from the kit) over the cable splice.

Applies to the XC90

• Take the radiated heat shield from the kit. Pull the radiated heat shield all the way up to the engine block heater so that the cable splice and the plastic surround are completely covered.

  
  

  Note! It is important that the radiated heat shield covers the entire joint cable to the engine.

  
  

• Secure the radiated heat shield around the cable to the engine block heater. Use a grey heat resistant tie strap in the lower edge of the radiant heat shield.

Applies to the XC90

• Take a screw, spacer sleeve and tensioner from the kit. Secure the engine block heater to the cylinder block. Tighten the screws to the engine block heater. Tighten to 16 Nm (12 lbf. ft.).

• Remove the existing nut from the steering gear

• Install the mounting bracket for the junction switch and cables

• Install the new lock nut supplied. Tighten to 48 Nm (36 lbf. ft.).

Applies if the engine block heater and passenger compartment connector socket must are to be mounted at the same time

• Install the junction connector on the bracket using the screw and nut from the kit

• Lubricate the O-rings using low temperature grease, (P/N 1161417-9) (see point 15)

• Connect the wiring from the front engine block heater socket (1), the passenger compartment socket (2) and the engine block heater (3) to the junction connector

• Tighten the junction connector to the bracket for the steering gear.

Applies to all models Connection and finishing work

Applies to all models Connection and finishing work

• Press the four tie-straps (from the kit) into the holes on the inside of the sub-frame

• Route the cable from the front engine block heater socket above the front edge of the sub-frame and backwards to the cable from the engine block heater

• Secure the cable in the installed tie straps

• Lubricate the O-rings on the connector using low temperature grease, (P/N 1161417-9) (see point 15).

• Route the cable from the engine block heater over the oil cooler to the previously installed bracket

• Take the double clamp (1) from the kit. Secure the cable at the left-hand hose on the oil cooler and at the right-hand pipe using a tie-strap (2) from the kit as illustrated.

  
  

  Note! Ensure that the cable is secured properly at the oil cooler so that it does not rub against the drive shaft.

  
  

• Connect the cable from the front engine block heater socket to the cable from the engine block heater. Alternatively connect the cable to the junction connector

• Press the locking sleeves (from the kit) over the cable splices

• Press one clamp (from the kit) into the hole on the previously installed bracket

• Secure the cable at the bracket as illustrated.

  
  

  Note! The cable must not be secured to the drive shaft, to the fuel lines, air conditioning (A/C) pipes or brake pipes. Ensure that the cable is not rubbing against any sharp edges and that it is not too close to the turbocharger (TC) or exhaust pipe to prevent damage from radiant heat.

  
  

Applies to the XC90

• Reinstall the stay to the cylinder block and exhaust pipe. Tighten the screws. Tighten to 24 Nm (18 lbf. ft.).

Applies to the S60 and V70 (00-)

• Reinstall the centre air baffle

• Clamp the engine block heater cable in the left mounting on the centre air baffle

• Reinstall the two air baffles at the sides.

Applies to all models

• Reinstall the engine splash guard. Tighten the engine splash guard screws. Tighten to 19 Nm (14 lbf. ft.).

Applies to the XC90

• Connect and reinstall the headlamp.