Installation Instruction

Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
S40 2012
S40 (04-) 2012 L.H.D

Instruction NoVersionPart. No.Click to download PDF-version of this Installation Instruction
307568651.231373137, 30756864
Electric engine heater, 230 V, 5-cyl. diesel




IMG-247803




 
Equipment
A0000162
IMG-239660
IMG-239664
IMG-239667

IMG-332913

IMG-333598

IMG-364592

IMG-265776


 
  

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-316263
 

2
J8000359
 

Applies to the S40/V50

  • Remove the seven screws from the engine splash guard.

3
J8601130
 

  • Remove the left front wheel.

  • Remove the five screws holding the bumper cover in the wing liner on the left and right-hand sides.

4
IMG-265763
 

  • Remove the four screws.

5
J8601087
 

  • Push in the centre of the five clips (1). Remove the clips.

  • Remove the two screws (2).

6
J8601084
 

  • Remove the covers for the nozzles for the headlamp washers on the right and left-hand sides. Carefully grip the cover. Pull the cover out until the catch becomes accessible.

7
J8903376
 

  • Press the catch up. Remove the cover. Do not damage the painted surfaces or the washer nozzles

8
J8601086
 

  • Detach the ends of the bumper shell on the left and right-hand sides. Grasp the end of the bumper shell inside the fender liner. Carefully pull the end of the bumper shell so that the two catches on the inside release.

  • Remove the bumper cover and air baffle. Pull the bumper cover and air baffle forwards until the remaining catches under the lamps release.

  • Disconnect the connectors for the fog lamps and parking assistance if applicable.

9
IMG-265777
 

  • Cut out the template by cutting along the outer edges of the dotted and solid line.

  • place the template with the dotted section on the existing marking (perforation) on the bumper. Mark according to the new, slightly recessed marking.

  • Cut off the upper dotted section of the template and finish the new marking all the way around.

10
IMG-265778
 

  • Using a sharp knife, first make a thin cut along the edges of the new marking inside of the bumper cover. Then carefully cut out the bumper cover hole.

  • Cut off the upper dotted section of the template and finish the new marking all the way around.


Warning!

Cut carefully. It is easy to slip with the knife and move outside the markings.


  • 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.

11
IMG-265779
 

  • Take the protective cover from the kit and press it into 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.

12
IMG-265781
 

  • Install the mounting and nut from the kit. Connect the connector to the front engine block heater socket. Use the connector as a counterhold when tightening.

13
IMG-265782
 

  • Turn the front intake's connector so that the cover opens forward.

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

14
IMG-332924
 

Applies to the C70

  • Clean the bumper cover where the wing template is to be positioned.

  • Wipe dry.

15
IMG-332914
 

  • Find the template for C70 MY 2010 in the installation instructions. Cut it out following the dotted lines.

16
IMG-332916
 

  • Position the templates following the curves of the surface between the lower grille and panel for the fog lamps and tape it according to the image.

  • 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.


Warning!

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.

17
J8601130
 

  • Remove the left and right-hand front wheels.

  • Remove the five screws holding the bumper cover in the wing liner on the left and right-hand sides.

  • Remove the screws (2).

18
J8601131
 

  • Remove the nut holding the left-hand wing liner to the front member.

  • Bend the front edge of the left-hand wing liner up over the brake calliper.

19
IMG-225652
 

  • Remove the covers for the nozzles for the headlamp washers on the right and left-hand sides. Carefully grip the cover. Pull the cover out until the catch becomes accessible.

20
IMG-332933
 

  • Carefully pull the hooks to the side and remove the cover. Repeat on the other side.

21
IMG-227800
 

  • Press in the centre of the clips (1) and remove them. Remove the screws (2).

22
IMG-225649
 

  • Detach the right and left-hand ends of the bumper.

  • Grip the bumper from the inside and pull it forward in order to detach the two holders under the headlamps.

  • Remove the bumper, unplug the connectors for the fog lamps and place the bumper on a surface that does not damage the paintwork.


Hint

This procedure is easier carried out by two people.


23
IMG-332938
 

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

  • Insert the cable for the front engine block heater socket together with the ground lead from the kit through the protective cover.

24A
IMG-332939
24B
IMG-332943
 

Illustration A

  • Install the mounting and nut from the kit. Connect the connector to the front engine block heater socket. Use the connector as a counterhold when tightening.

Illustration B

  • Turn the front intake connector so that the cover opens outwards to the side.

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

25
IMG-225646
 

  • Remove the screws holding the engine splash guard and remove the guard.

26
IMG-332918
 

Applies to the C30

  • Remove the front wheels.

27
IMG-331946
 

28
IMG-331947
 

  • Remove the screws from in the right and left fender liner and the plastic nut in the left fender liner.

29
IMG-331948
 

30
IMG-332920
 

  • Carefully pry off the panel at the lower edge and remove it. Place to one side. A new one can be found in the kit.

31A
IMG-331989
31B
IMG-331990
 

Illustrations A and B

  • Take a new panel, front intake cable with washer and nut from the kit.


Note!

The washer must be positioned as illustrated.


  • Insert the cable and ground lead through to the engine heater. Ensure the connector is turned so that the cover's sides are parallel with the plates in the panel and that the cover opens from the panel's left-hand side (Image B).

  • Tighten the connector.

32
IMG-331991
 

  • Insert the cable through the oval smaller of the holes behind the panel.

  • Press the panel into place.

33
IMG-225640
 

Applies to all car models where the bumper cover is removed

  • Reinstall the bumper cover. Use the five clips and the two screws at the top edge. Ensure that the air baffle is correctly positioned in its mounting.

  • Press in so that the clips under the headlamps fasten.

  • Reconnect the connectors for the fog lamps and parking assistance if applicable.


Hint

This procedure is easier carried out by two people.


34
J2900313
 

Applies to all models

    Cable routing

  • Install three clips from the kit on the panel edge on the underside of the left front member

35
IMG-360291
 

  • Route the front intake cable from the front edge of the washer fluid reservoir, along the bottom edge of the front member and over the drive shaft. Route the cable a bit into the engine compartment.

  • Press the cable into the previously installed clips.

36
IMG-339147
 

37
IMG-339151
 

38
J2900297
 

  • Secure the cable in the hole on the bracket for the front left radiator mounting. Use a cable tie (1) from the kit.

39
J2900298
 

  • Drill a Ø4 mm (5/32) hole for the ground lead, on the outside of the left-hand front member, approximately as illustrated.

  • Treat the edges of the holes using a rust-proofing agent.

40
J2900299
 

  • Secure the ground lead in the drilled hole. Use the screw and toothed washer from the kit.

  • Affix the excess length of ground lead at the existing clips.

41
IMG-232644
 

  • Install three clips from the kit on the front edge of the panel above the windscreen wiper motor.

  • Guide the cable up to the top of the engine compartment to the position illustrated.

42
IMG-339141
 

43
IMG-232645
 

  • Press the front intake cable into the clips. Guide down the cable at point (1) and route down through the engine compartment down to the strut in the right link arm mounting.

  • Secure the cable, from the top of the engine compartment and down, using a cable tie at the existing cable harness.


Note!

Do not clamp the cable directly to AC pipes, fuel lines, brake pipes or power steering hoses and pipes. Make sure the cable does not chafe against sharp edges or moving parts in the engine compartment.


44
IMG-339146
 

45
D3601932
 

  • Lubricate the O-rings on all cables for the engine block heater and if the car is to have a passenger compartment connector/timer relay, also lubricate the O-rings on these with low temperature grease P/N 1161417.


Note!

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


46
J2900302
 

Applies to cars where the engine block heater and passenger compartment connector socket are installed at the same time

  • Take the bracket and the rubber guard from the kit for the passenger compartment connector socket. Press the rubber guard on to the bracket.

47
J2900296
 

  • Tighten the junction connector at the bracket (included in the kit for the passenger compartment connector socket) in the position illustrated. Use the screw, toothed washer and nut from the kit. The bracket must be parallel to the length of the junction connector.

  1. Cable to engine block heater

  2. Cable to passenger compartment connector

  3. Cable from front intake

48
J2900303
 

  • Tighten the timer relay at the bracket (purchased separately) in the position illustrated. Use the screw, toothed washer and nut from the kit. The bracket must be parallel to the length of the timer relay.

  • Connect the connector on the long cable harness (from the kit) to the timer relay.

  1. Press the rubber plug (1), part no. 346509, (purchased separately) into place on the free socket in the timer relay. Use butyl tape to secure the rubber plug.

  2. Position (2) cable for the engine block heater

  3. Position (3) cable from the front engine block heater socket.

49
J2900304
 

  • Tighten the timer relay at the bracket (purchased separately) in the position illustrated. Use the screw, toothed washer and nut from the kit. The bracket must be parallel to the length of the timer relay.

  • Connect the connector on the long cable harness (from the kit) to the timer relay.

  • Connect the connector on the long cable harness (from the kit) to the timer relay.

  1. Position (1) cable for the passenger compartment socket

  2. Position (2) cable for the engine block heater

  3. Position (3) cable from the front engine block heater socket.

50
J2900292
 

  • Connect the short cable from the kit to the engine block heater, to the routed cable (1) from the front socket. (When fitting junction connector/timer relay at the same time, the cable from the front socket is connected to the single outlet on the junction connector/timer relay instead. Refer to the installation instructions for passenger compartment socket/timer relay).

  • Firmly press the cable junction together.

51
J2900293
 

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

52
J2900294
 

  • Take a double tie strap from the kit. Install the double tie strap around the stay and the cable splice. Ensure that the splice is secured in the centre of the strut. Tighten the double clamp properly.

53
IMG-339016
 


Note!

Be prepared to collect liquid that runs out.


  • Tighten the valve when the coolant has drained.

54
IMG-316564
 

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

55
IMG-316566
 

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

56
IMG-316568
 

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

57
IMG-316571
 

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

58
IMG-316583
 

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

  • Tighten the hose clamp securely.

59
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.


60
IMG-214122
 

  • 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.

61
IMG-316743
 

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

  • 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.

62
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.


Caution!

Ensure that the hoses do not catch the charge air pipe.


63
IMG-235624
 

  • Take the radiation shield from the kit and thread on the joint cable of the heater.

64
IMG-340340
 

  • Take the radiation shield from the kit and thread on the joint cable of the heater.

65
IMG-340339
 

  • Fasten the heater cable to the turbocharger pipe using a double tie strap from the kit.

66
IMG-340337
 

  • Connect the short electrical cable (which was routed earlier) to the engine block heater. Press it firmly into the engine block heater connection.

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

67
IMG-340336
 

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

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

68
 

Reinstall the detached components in reverse order.

Fill with coolant and run the engine to operating temperature.