Preparations

Preparations

• Undo the clamp for the intake hose and pull the hose off.

Applies to the S80

• Use isopropanol to clean the bumper shell where the cutting template for the front engine block heater socket is to be secured.

• Wipe dry.

• Take the template from the kit and cut it along the dotted lines.

• Remove the protective backing tape from the template and secure the template edge to edge with the front edge of the front wing and embossing in the bumper cover as illustrated.

• Take a sharp knife. First make a thin cut along the edges of the inside of the template. This provides a groove to follow. Then cut carefully out the bumper cover.

  
  

  Note! Cut carefully. It is easy to slip with the knife and move outside the template.

  
  

• Remove the template and tape pieces.

• Install the protective cover for the front engine block heater socket from the kit. Check that it aligns. Adjust the hole using a knife or file as necessary.

• Smooth off the hole edges. Remove any swarf.

Applies to the V70

• Find the template for the front intake in the installation instructions. Cut it out following the dotted lines.

• Attach the template using tape edge to edge with front edge of the front wing and the embossing in the bumper cover as illustrated.

• Take a sharp knife. First make a thin cut along the edges of the inside of the template. This provides a groove to follow. Then cut carefully out of the bumper cover.

  
  

  Note! Cut carefully. It is easy to slip with the knife and move outside the template.

  
  

• Remove the template.

• Install the protective cover for the front engine block heater socket from the kit. Check that it aligns. Adjust the hole using a knife or file as necessary.

• Smooth off the hole edges. Remove any swarf.

Applies to the XC60

• Clean the marked surface using isopropanol and wipe dry.

• Find the template for the front intake in the installation instructions. Cut it out following the dotted lines.

• Attach the template using tape edge to edge with front edge of the front wing and the joint in the bumper cover as illustrated.

• Take a sharp knife. First make a thin cut along the edges of the inside of the template. This provides a groove to follow. Then cut carefully out of the bumper cover.

  
  

  Note! Cut carefully. It is easy to slip with the knife and move outside the template.

  
  

• Remove the template.

• Install the protective cover for the front engine block heater socket from the kit. Check that it aligns. Adjust the hole using a knife as necessary.

• Smooth off the hole edges. Remove any swarf.

Applies to all models

• Press the protective cover (from the kit) into place in the hole cut in the bumper cover.

• Take the cable for the front engine block heater socket with ground lead from the kit and thread them through the protective cover.

Illustrations A and B

• Install the attaching brace and nut from the kit.

• Rotate the connector for the front engine block heater socket carefully so that the cover opens backwards (Illustration B).

• Plug the electrical connector into the front engine block heater socket. Use the connector as a counterhold when tightening.

• Tighten the front engine block heater socket to the bumper shell.

• Press the cable into the holder on the washer fluid reservoir.

• Remove the cover on the radiator expansion tank.

Illustrations A and B

• Route the cable with the ground cable from the front engine block heater socket in front of the left-hand front mounting for the subframe and down on the inside of the subframe.

Illustration A

Applies to the S80 and V70

• Drill a Ø 4mm (Ø 5/32 ") hole for the front intake grounding on the underside of the left front side member as illustrated.

• Deburr the hole edges, remove the drill swarf and apply rustproofing agent.

• Take a screw and toothed washer from the kit. Tighten the ground cable.

Illustration B

Applies to the XC60

• Drill a Ø 4mm (Ø 5/32 ") hole for the front intake grounding on the inside of the left front side member as illustrated.

• Deburr the hole edges, remove the drill swarf and apply rustproofing agent.

• Take a screw and toothed washer from the kit. Tighten the ground cable.

Installing the engine block heater

Installing the engine block heater

• Drain the coolant.

• Tighten the nipple after draining.

• Pull the intake hose down and secure it at the sub frame.

• Take a spacer sleeve from the kit and tighten in the right-hand hole on the front side of the engine above the joint between the engine block and oil sump.

• Take the heater and clamp from the kit and assemble as illustrated.

• Take screws from the kit and tighten the heater in the spacer sleeve.

Illustrations A and B

• Cut the hose (1) as follows:

Measure out for cutting the coolant hose between the oil cooler and the thermostat housing.

Position the hose at the heater's lower connection, ensure that it runs around the oil filter properly and cut it.

• Smooth off the hose ends if necessary. Do not cut off too much of the hoses.

• Take hose clamps and tighten the hoses to the heater, preferably from underneath.

• Take the clip with tie strap for a Ø 6.5 mm (Ø1/4 ") hole and press it into the left hole on the inside of the upper edge of the subframe.

• Take the two clips from the kit and press them onto the sub frame's upper/front edge and at the left front-edge of it.

• Position the clip that is to be nearest the cable tie fitted previously according to the measurements specified in the image.

• Lubricate the O-ring on the connector on the cable from the front engine block heater socket with low temperature grease.

If the passenger compartment connector socket is to be installed at the same time then install the junction connector now in accordance with illustration C and D, and connect the cables to it.

Illustration A

• Take the joint cable to the engine block heater from the kit and connect to the cable from the front engine block heater socket. Press the connectors together firmly and secure a locking sleeve from the kit over the cable splice.

Illustration B

• Clamp the cable splice (1) to the inside of the subframe using the cable tie and press the cable into the clips.

Illustration C

Applies when fitting passenger compartment connector at the same time

• If the passenger compartment connector is to be installed at the same time, install the junction connector now. Lubricate the O-rings on the contacts as previously.

• Connect:

cable (1) from the front intake

cable (2) to the passenger compartment connector socket

cable (3) to the heater.

Illustration D

Applies when fitting passenger compartment connector at the same time

• Insert the junction connector into the space in the sub frame. Tighten the junction connector with the cable tie around the outer connector of the two on the junction connector. The position of the edge clip at the upper edge of the sub frame's left-hand side may need adjusting in order to fit the junction connector.

• Lubricate the O-ring on the connector on the jointing cable with low temperature grease.

• Firmly secure the cable into the heater's connector.

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

• Move the intake hose up into place and tighten the clamp. Ensure that it ends up on the correct side of the cable to the heater.

• Clamp the cable splice around the intake hose using a double cable tie and edge clips with cable tie on the inside of the upper edge of the sub frame.

• Fill with coolant and warm up the engine. Bleed the cooling system and check for leaks.

• Top up the cooling system as required.