2007 L.H.D

Installation Instruction

Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
S80 2007
S80 (07-) 2007

Instruction NoVersionPart. No.Click to download PDF-version of this Installation Instruction
306604981.130660489
Electric engine block heater, 110V, 8 cyl




Equipment
A0000162
A0000163
A0000161

IMG-231307

IMG-213320


 
  

INTRODUCTION

  • Read through all of the instructions before starting installation.

  • Notifications and warning texts are for your safety and to minimise the risk of something breaking during installation.

  • Ensure that all tools stated in the instructions are available before starting installation.

  • Certain steps in the instructions are only presented in the form of images. Explanatory text is also given for more complicated steps.

  • In the event of any problems with the instructions or the accessory, contact your local Volvo dealer.

1
IMG-231308
 

  • Remove the left-hand cover panel under left-hand headlamp by first carefully prizing loose the right-hand end face until the four clips on the inside release, following which, pull it out to the right.


    Note!

    Do not damage the paintwork.


2
IMG-231309
 

  • Remove the engine splash guard.

3
IMG-231310
 

  • Drill out the marked hexagonal surface and cut/file until it is level at the edges.

  • Drill a Ø 8.5 mm (21/64 ") diameter hole in the hexagonal surface (1) approximately as illustrated.

4A
R2900279
4B
R2900280
4C
R2900283
4D
R2900281
 

    Illustration A, B, C and D

  • Take the front engine block heater socket's components from the kit and assemble the front engine block heater socket as illustrated.

5A
IMG-231311
5B
IMG-231312
 

    Illustrations A and B

  • Secure the front engine block heater socket's connector into the panel.

6A
IMG-231313
6B
IMG-231314
6C
IMG-231315
 

    Illustrations A, B and C

  • Route the front engine block heater socket's cable on the inside of the strut, over/inside the left-hand front corner of the subframe and let it hang down as illustrated.

7
IMG-231316
 

  • Press in the panel with the connector in its location.

8
IMG-231317
 

  • Remove the four screws in the strut under the exhaust manifold and remove the strut.

9
IMG-231318
 

  • Detach the rubber mountings from the exhaust manifold.

10A
IMG-231319
10B
IMG-231320
10C
IMG-231321
 

Illustration A

  • Remove the nuts in the rear joint by the front silencer.

Illustration B

  • Remove the screws in the front joint.

Illustration C

  • Remove the exhaust manifold.

New gaskets, screws and nuts must be used for installation.

11
R2900483
 

  • Detach the engine block drain nipple under the left-hand side of the rear manifold and drain the coolant.

  • Tighten the nipple when the coolant is drained.

12A
R2900484
12B
R0801929
12C
R3603708
 

Illustration A

  • Remove the plug in the engine block under the left-hand side of the rear manifold.

Illustration B

  • Use hexagon socket P/N 9512965, socket extension 120 mm (4 ¾ ") with spherical end, socket extension 500 mm (19 11/16 ") with spherical end and handle.

Illustration C

  • Apply a piece of butyl tape on the hexagon socket so that the plug does not fall away when it is unscrewed.


    Note!

    Removing the plug requires significant force.


13
R2900485
 

  • Take the heater from the kit and install it in the engine block.


    Hint

    Rotate the connector around in the heater's thread to reduce any friction.


  • Brush thread sealant P/N 1161056 on the threads.

  • Engage the threads in the engine block by turning the whole heater clockwise until the connector reaches the stop position. Guide the threaded section of the engine block heater with one hand and turn with the other. Hold the threaded section firmly with one hand and rotate the connector anticlockwise to the stop position with the other. Rotate the whole heater body clockwise again to the stop position and repeat until the heater is screwed into the engine block.


    Note!

    Make sure that the heater has engaged the threads properly before tightening.


14A
R0801928
14B
R3603707
 

Illustration A

  • Take tool P/N 9814012, a ½ "- 3/8" adapter, the two socket extensions and a ½ " ratchet handle.

Illustration B

  • Tighten the heater firmly to the engine block.

15
IMG-231322
 

  • Press the three clips from the kit into the panel edge on the inside of the subframe.

16
IMG-231323
 

  • Route the cable up in the rear edge of the gearbox and on to the engine block heater.

17
IMG-225580
 

  • Lubricate the O-ring on the connector for the engine block heater's cable with low temperature grease P/N 1161427.


    Note!

    Do not get any grease on the surfaces of the connector.


18
IMG-231324
 

  • Take the radiation shield from the kit and thread it onto the cable from the front engine block heater socket.

19A
IMG-231325
19B
IMG-231326
 

Illustration A

  • Firmly press in the connector to the engine block heater.

Illustration B

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

  • Check that the cable does not chafe against moving parts or sharp edges in the engine compartment. Use tie straps from the kit to secure the cable.


    Note!

    Do not clamp the cable so that it is in direct contact with brake pipes, fuel lines, AC pipes or pipes to the power steering.


20
IMG-231327
 

  • Pull the radiation shield up so that it fully covers the connector on the engine block heater.

  • Take the grey tie strap from the kit and clamp the radiation shield by the heater in the upper edge.

21
IMG-231328
 

  • Press the cable into the three clips.

22
IMG-231329
 

  • Take a tie strap equipped with clip from the kit and clamp in the cable and any excess cable in the existing hole in the subframe.

23A
IMG-231330
23B
IMG-231331
23C
IMG-231332
23D
IMG-231333
 

    Illustration A, B, C and D

  • Make sure that all sealing surfaces are thoroughly cleaned and reinstall the exhaust manifold with new gaskets, clamp nuts and screws from the kit. Torque tighten to 25 Nm (18.5 lbf.ft.).

24
IMG-231334
 

  • Reinstall the strut and tighten the screws to 60 Nm (44 lbf.ft.).

25
 

  • Fill with coolant, drive to normal operating temperature and bleed the system. Check that there are no leaks.

  • Top up the cooling system as required.

26
IMG-231335
 

  • Reinstall the engine splash guard. Tighten.