Installation Instruction

Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
V60 Cross Country 2018
V60 Cross Country (-18) 2018 D5244T21 TF-80SD AWD

Instruction NoVersionPart. No.Click to download PDF-version of this Installation Instruction
313995061.031664098, 31260698, 31664097
Electric engine heater, 230 V




IMG-378205




 
Equipment
A0000162
IMG-239664
IMG-239660

IMG-344427

IMG-378047


 
  

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-363036
 

Color symbols


Note!

This colour chart displays (in colour print and electronic version) the importance of the different colours used in the images of the method steps.


  1. Used for focused part, the part that you are to do something with.

  2. Used as extra colors when you need to show or differentiate additional parts.

  3. Used for attachments that are to be removed/installed. May be screws, clips, connectors, etc.

  4. Used when the component is not fully removed from the vehicle but only hung to the side.

  5. Used for standard tools and special tools.

  6. Used as background color for vehicle components.

2
IMG-316263
 

Removal

3
IMG-341077
 

  • Remove the right-hand front wheel.

4
IMG-341082
 

  • Remove the five screws in the leading edge of the wing liners on both sides.

  • Remove the plastic nuts that hold the wing liners at the body on both sides.

5
IMG-341081
 

  • Fold the wing liners to one side on both sides.

6
IMG-378206
 

  • Use isopropanol to clean the bumper cover where the cutting template for the front intake is to be secured.

  • Wipe dry.

7
IMG-378210
 

  • Use the template from the installation instructions.

  • Cut out following the dotted lines.

8
IMG-378213
 

  • Apply the template edge to edge with the line at the front edge of the front wheel arch and lower edge of the bumper cover.

9
IMG-378214
 

Accessory installation

  • 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 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.

10
IMG-341071
 

  • 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.

11A
IMG-342364
11B
IMG-342365
 

  • Install the attaching brace and nut from the kit.

  • 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.

  • Ensure that the front intake cover opens rearwards.

12
IMG-344646
 

Removal

13
IMG-340576
 

14
IMG-341072
 

Accessory installation

  • Route the cable with ground lead from the front intake behind the subframe's left-hand front mounting.

15
IMG-342366
 

  • Continue downwards on the inside of the subframe.

16
IMG-341074
 

  • Clamp the cable in the hole at the left-hand front mounting in the subframe.

17
IMG-231571
 

  • Drill a Ø4mm (Ø5/32 ") 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.

18
IMG-316303
 

  • Drain the coolant.

  • Tighten the nipple after draining.

19
IMG-316564
 

  • Remove the hose clamp, pull loose the hose from the oil cooler and let the remaining coolant drain.

20
IMG-316566
 

  • Install the hose again and cut it off approx. in the middle of the straight hose elbow.

21
IMG-316568
 

  • Pull loose the hose end and throw it away. New hose and nipple are included in the kit.

22
IMG-316571
 

  • Get a junction nipple from the kit and insert half of it in the remaining hose part.

23
IMG-316583
 

  • Take hose clamp from the kit and tighten down the nipple.

  • Tighten the hose clamp securely.

24
IMG-214121
 

  • Take a bracket, two bolts and washers from the kit. Fasten the bracket in the existing holes on the left side of the oil cooler.


Note!

The screws are self-tapping so it may be slow inserting them. Make sure that the screws are centred straight into the holes, so that the screw heads are flat against the bracket.


25
IMG-214122
 

Applies to vehicles with 2 wheel drive

  • Take the heater, rubberized clamp and bolt from the kit. Fasten the heater with the clamp in the upper hole in the bracket. The hose connections on the heater should point backwards.

26
IMG-214125
 

Applies to vehicles with 4 wheel drive

  • Take the heater, rubberized clamp and bolt from the kit. Fasten the heater with the clamp in the lower hole in the bracket. The hose connections on the heater should point backwards.

27
IMG-377570
 

Applies to all vehicles

  • Get junction cable and two hose clamps from the kit.

  • Cut off the hose as illustrated.

28
IMG-316743
 

  • Install the hose between the earlier installed junction nipple and the upper connection in the engine heater.

  • Tighten the clamps securely. Make sure that the hoses do not rub against the drive shaft or hose clamps.

29
IMG-316744
 

  • Get the last junction hose and the two remaining hose clamps from the kit. Connect the junction hose between the remaining connections in the engine heater and the oil cooler.

  • Tighten the clamps securely.

30
IMG-317737
 

  • Take the clip with tie strap for a Ø 6.5 mm (1/4 ") hole and press it into the left hole on the inside of the upper edge of the subframe.

31
IMG-344611
 

  • Take four clips from the kit and press them into place on the upper/front edge of the subframe.

32
D3601932
 

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


Note!

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


33
IMG-214136
 

Applies when only the engine block heater is installed

  • Connect the extension cable of the engine heater with the cable from the front intake. Press the connectors together and press a locking sleeve from the kit over the splice.

34
IMG-317743
 

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

35
IMG-231576
 

Applies when fitting passenger compartment connector at the same time

  • Connect:

  • cable (1) from heater

    cable (2) to the passenger compartment connector socket

    cable (3) to the front inlet

36
IMG-317744
 

  • Insert the junction connector in the space in the sub-frame and tighten down the junction connector around the rear cable with a cable tie in the hole at the top of the sub-frame.

37
IMG-342111
 

Applies to all vehicles

  • Continue to pull the cable up around the subframe's right-hand mounting between the power steering pump and body.

38
IMG-342114
 

39
IMG-342112
 

  • Continue to pull the cable down along the hose to the power steering pump to the inside of the subframe.

  • Clamp using cable ties with clips.

40
IMG-407095
 

  • Install edge clip as illustrated.

41
IMG-344456
 

  • Take the radiation shield from the kit and thread it on the extension cable.

42
IMG-344457
 

Applies to AWD

  • Press the routed extension cable fully into the heater and press a lock sleeve over the splice.

43
IMG-344461
 

  • Reposition the radiation shield so that it covers the entire heater connector.

  • Fasten the radiation shield to the heater's connector with the grey cable tie from the kit.


Note!

Make sure that the cable is routed so that it does not come into contact with the belt pulley, AC compressor belt or the drive shaft.


44
IMG-406766
 

Applies to FWD

  • Position the part as illustrated.

45
IMG-406765
 

  • Plug in the connector.

46
IMG-317784
 

Applies to all models

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

47
IMG-340577
 

48
IMG-344757
 

49
IMG-341107
 

50
IMG-341082
 

51
IMG-341106