Electric Engine Block Heater

Electric engine block heater








































Electric engine block heater

Points 1-4 apply to the S80




- Secure the adhesive template. Use the template to mark up the bumper for holes
- Drill a hole. Use a 4 mm (5/32") diameter drill bit
- Drill a hole at right-angles to the surface. Use a 29 mm (1 1/8") diameter hole saw
- Adjust the guide hole using a round file
- Also adjust the lead-in hole if necessary.




- Open the drain holes on both sides. Use a screwdriver. Press in by hand at the markings.




- Install the expander nut in the hole, with the locating pin in the guide hole
- Route the cable, including the ground lead, from the front socket from above and downwards. Let the cables hang down to the ground.




- Connect the cable to the front engine block heater socket
- Press downwards and turn the cable clockwise so that the expander nut engages
- Align the cable from the front socket so that the hinge is pointing towards the headlamp
- Remove the connection cable.

Points 5 -9 apply to the XC70




- Clean the bumper cover where the two pieces of tape will be secured
- Apply two pieces of tape to mark the holes for the engine block heater switch (use thin tape). Apply one piece of tape at the rear edge, under the corner of the indicator lamp, vertically down. Position the underside of the second piece of tape along the upper radius of the bumper cover as illustrated.




- Mark up a rectangle on the inside of the corner where the two pieces of tape intersect. See the measurements in the illustration. The distance from the edges of the tape must be 5 mm (13/64")
- Apply tape to the surface of the bumper which is to be cut. This is to protect the bumper skin
- Carefully cut out the bumper cover. Follow the markings. Use a utility knife or similar
- Even off the edges.




- Remove the pieces of tape
- Take the protective cover (1) for the front engine block heater socket from the kit. Press the protective cover into the cut out. Ensure that the section of the cover where the hole is nearest the edge is pointing forwards
- Mark out the hole in the bracket (2) inside the bumper cover. Use a 29 mm (1 1/8") diameter hole saw without the central drill bit
- Remove the protective cover. Drill out the hole using a 29 mm (1 1/8") diameter hole saw
- Remove any swarf.




- File out a small 4 x 4 mm (5/32" x 5/32") cut out in the lower edge of the hole in the protective cover. The hole is intended for the lug on the expander nut. This is used to secure the front engine block heater socket
- Reinstall the protective cover.




- Install the expander nut (1) in the hole
- Thread the cable supplied (2), including the ground lead, through the hole
- Take the connection cable (3) from the kit. Assemble it using the cable at the expander nut. Screw clockwise so that the expander nut expands
- Remove the connection cable.

Note! Ensure that the drainage hole for the front engine block heater socket is open.

Applies to all models and engine variants, except Diesel (TDI)




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

Points 11-13 apply to all models




- Raise the car
- Remove the screw (1) from the left air baffle (2) for the front brake
- Pull the left air baffle backwards. Remove the left air baffle
- Remove the right air baffle in the same way.




- Remove the screws (1). Remove the air baffle (2)
- Remove the screws (3). Remove the splash guard (4).




Ground terminal for the cable under the member
- Drill a hole. Use a 4 mm (5/32") diameter drill bit
- Rust-proof and secure the ground lead. Use the 4.8 mm (3/16") diameter flanged screw and toothed washer included.

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

- Secure any excess ground lead. Use new tie straps.

Points 14-15 apply to cars with five cylinder engines and a stay for the turbo unit




- Remove the stay.




- Clean the area where the heater will be positioned. This ensures optimal heat conduction to the cylinder block. Also clean the internal thread
- Thread the heat shield over the cable for the heater
- Take the locking sleeve and the cable for the heater from the kit. Connect the cable to the heater. Install the locking sleeve over the joint on the cable
- Install the heater on the cylinder block, as illustrated
- Install the spacer washer (1), t=10 mm / 25/64", between the tensioner (2) and the mounting (3) in the cylinder block
- Install the outer spacer washer (4), t=32 mm / 1 1/4", between the stay and the tensioner (2)
- Screw the heater into place. Use the screw from the kit. Tighten to 16 Nm (12 lbf.ft.).

Points 16-18 only apply to TDI engines and immersion heaters




- Open the cover for the radiator expansion tank
- Position a container under the engine. Open the coolant drain cock
- Drain the coolant. Close the drain cock.




- Pull out the core plug located in the middle of the cylinder block. Use an extractor.




- Thread the O-ring on to the heater
- Lubricate the O-ring. Use low temperature grease, (P/ N 1161427)
- Screw the immersion heater into the cylinder block. Tighten to 3.5 Nm (2.6 lbf.ft.)
- Take the locking sleeve and the cable for the heater from the kit. Connect the cable to the heater. Install the locking sleeve over the joint on the cable
- Secure the cable at the pipe on the right-hand side at the rear edge of the sub-frame. Use a tie strap from the kit.

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

Applies to cars with five cylinder engines without a stay for the turbo unit

Illustration A




- Clean the area where the heater will be positioned. This ensures optimal heat conduction to the cylinder block. Also clean the internal thread
- Thread the heat shield over the cable for the heater
- Take the locking sleeve and the cable for the heater from the kit. Connect the cable to the heater. Install the locking sleeve over the joint on the cable
- Install the heater on the cylinder block, as illustrated
- Install the spacer washer (1), t=10 mm / 25/64", between the tensioner (2) and the mounting (3) in the cylinder block
- Install the outer spacer washer (4), t=32 mm / 1 1/4", outside the tensioner (2)
- Screw the heater into place. Use the screw from the kit. Tighten to 16 Nm (12 lbf. ft.).

Illustration B




- Pull the 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 heat shield completely covers the cable splice on the engine side.

- Secure the heat shield around the cable to the engine block heater. Use a grey, heat resistant tie strap and clamp the bottom edge of the heat shield.

Applies to five cylinder cars with a stay for the turbo unit from model year 2005- (XC70 CH 173000-, S80 CH 390000-)

Illustration A




- Knock away the spacer (1) from the stay. Grind off the welds if the spacers are tightly installed.

Illustration B




- Clean where the heater is to be located for optimum heat conduction to the cylinder block. Also clean the internal thread.

Hint: To facilitate installation of the heater on the cylinder block, first secure the tensioner (2) by the heater. Use a small piece of butyl tape. Then also secure the spacer sleeve (1) on the reverse of the tensioner. Use a small piece of butyl tape.

Note! The outward curved section of the tensioner must point away from the heater.

- Install the spacer washer (1), (t=10 mm (25/64")) between the tensioner (2) and the mounting in the cylinder block (3). Install the outer spacer washer (4) (t=32 mm (1 1/4")) on the outside of the bracket
- Thread the long screw (5) through to hold everything in place.

Illustration C




- Thread the heater and tensioner in place. Screw the turbocharger (TC) stay into place using the three screws as follows:
- Screw the turbocharger (TC) stay into place through the tensioner in the cylinder block. Use the long screw (1)
- Screw the turbocharger (TC) stay into the turbocharger (TC). Use the short screw (2). Screw the turbocharger (TC) stay into the other mounting in the cylinder block. Use the screw (3).
- Tighten the screws. Tighten to 16 Nm (12 lbf. ft.)
- Take the heat shield and cable from the kit. Thread the heat shield on the cable. Connect the cable to the heater
- Install the locking sleeve on the heater connector.

Applies to the S80 with six cylinders and automatic gearbox




- Detach the engine stabilizer brace (1) by slackening off the screws (2) at each end, and the nut and screw (3) in the engine mounting
- Remove the clamp for the servo hose on the right-hand side
- Remove the engine stabilizer brace.

Applies to the S80 with turbocharger (TC)




- Detach the charge air pipe (1) by slackening off the screw (2) and the hose clamps (3) at the rear edge
- Remove the pipe by pulling it forwards.

Applies to the S80 with six cylinders, turbocharger (TC) and automatic gearbox




- Disconnect the pipe (1) for the right-hand turbocharger (TC)
- Remove the screw and clamp (2) at the turbocharger (TC).

Applies to the S80 with six cylinders, turbocharger (TC), automatic gearbox and heated oxygen sensors (HO2S) mounted by the turbo unit

Illustration A




- Disconnect the cables for the heated oxygen sensors (HO2S) from the clamp on the pipe to the turbo unit
- Remove the two heated oxygen sensors (HO2S) by the turbo unit.

Note! Twist the cables together when unscrewing the heated oxygen sensors (HO2S). Ensure that the cables are twisted along as great a length as possible to minimize the risk of damage. Keep them twisted.

- Mark up the heated oxygen sensors (HO2S) so that they are reinstalled in the correct position and are not mixed up.

Illustration B




- Clamp the heated oxygen sensors (HO2S) with the twisted cables by the intake manifolds so that the cables resume their normal position when installing the heated oxygen sensors (HO2S). Use tie straps.

Points 25-27 apply to the S80 with six cylinders, turbocharger (TC) and automatic gearbox




- Slacken off the screws for the heat shields. Remove the screws
- Remove the heat shields.

Illustration A




- Clean the area where the heater will be positioned. This ensures optimal heat conduction to the cylinder block. Also clean the internal thread
- Install the heater on the cylinder block from the top.

Hint: First secure the tensioner (2) to the engine block heater. Use a small piece of butyl tape. Then secure the inner spacer washer (1), t =10 mm / 25/64", to the reverse of the tensioner. Use butyl tape.

- Insert the engine block heater into the cylinder block. Take the outer spacer washer (4), t=32 mm / 1 1/4", and the screw. Insert the screw through the outer spacer washer, into the hole in the tensioner and through the inner spacer washer
- Carefully move the engine block heater into position using the screw in the tensioner until the threaded cast protrusion (3) in the cylinder block is found
- Finger tighten the screw
- Take the extension cable and the heat shield from the kit. Thread the heat shield onto the extension cable
- Lubricate the O-ring on the extension cable. Use low temperature grease, (P/N 1161417-9).

Illustration B




- Take a locking sleeve from the kit. Connect the extension lead to the engine block heater. Press the locking sleeve into place over the joint
- Pull the heat shield all the way up to the engine block heater so that the cable splice and the plastic surround are completely covered.

Note! Ensure that the heat shield covers the entire joint towards the engine.

- Secure the heat shield around the cable to the engine block heater. Use a grey, heat resistant tie strap and clamp the bottom edge of the heat shield
- Tighten the engine block heater. Tighten to 16 Nm (12 lbf.ft.).

- Reinstall the heat shields.

Applies to the S80 with six cylinders, turbocharger (TC), automatic gearbox and heated oxygen sensors (HO2S) mounted by the turbo unit

Note! Do not mix up the heated oxygen sensors (HO2S).

- Lubricate the threads on the heated oxygen sensors (HO2S). Use paste (P/N 1161408)
- Reinstall the heated oxygen sensors (HO2S). Tighten to 45 Nm (34 lbf.ft.)
- Press the wiring for the heated oxygen sensors (HO2S) into place in the clamp on the intake manifold on the turbo unit.

Only applies to cars with turbochargers (TC)
- Reinstall the pipe for the right-hand turbo unit. See point 23
- Reinstall the charge air pipe. See point 22.

Applies to all models
- Reinstall the engine stabilizer brace across the engine. See point 21
- Tighten the screws. Tighten to 80 Nm (60 lbf.ft.). Tighten the screw and the nut. Tighten to 60 Nm (43 lbf.ft.).

Points 30-34 apply to cars with six cylinders, naturally aspirated engines and automatic gearbox




- Disconnect the hose for preheating the intake air.




- Remove the screws (1) for the preheating plate over the manifolds.




- Disconnect the cable to the right-hand heated oxygen sensor (HO2S) and the clamp (1) from the bracket (2)
- Remove the bracket.

Illustration A




- Remove the two heated oxygen sensors (HO2S) from the manifolds.

Note! Twist the cables together when unscrewing the heated oxygen sensors (HO2S). Ensure that the cables are twisted along as great a length as possible to minimize the risk of damage. Keep them twisted.

- Mark up the heated oxygen sensors (HO2S) so that they are reinstalled in the correct position and are not mixed up.

Illustration B




- Clamp the heated oxygen sensors (HO2S) with the twisted cables by the pipe for the air conditioning (A/C) system so that the cables resume their normal position when installing the heated oxygen sensors (HO2S). Use tie straps.




- Remove the preheating plate over the manifolds.

Points 35-38 apply to cars with six cylinders, naturally aspirated engines and automatic gearboxes, manufactured after week 35, 2001




- Remove the nuts in the flange at the joint between the manifolds and the exhaust pipes.




- Remove the screws for the front side impact protection member.




- Remove the brake pipe from the clamps in the side impact protection member
- Remove the clamp holding the cable to the left rear heated oxygen sensor (HO2S) from the side impact protection member
- Remove the side impact protection member
- Pull the exhaust pipes off the manifolds. Allow them to rest on the rear side impact protection member.




- Clean and spray rust solvent spray on the free ends of the studs for the left-hand manifold
- Remove the nuts (1) for the left-hand manifold mounting on the engine
- Pull the manifold off the exhaust pipe. Lift the manifold up from the engine. Place the manifold to one side.

Applies to the S80 with six cylinders, naturally aspirated engine and automatic gearbox

Illustration A




- Clean the area where the heater will be positioned. This ensures optimal heat conduction to the cylinder block. Also clean the internal thread
- Install the heater on the cylinder block from the top.

Hint: First secure the tensioner (2) to the engine block heater. Use a small piece of butyl tape. Then secure the inner spacer washer (1), t =10 mm / 25/64", to the reverse of the tensioner. Use butyl tape.

- Insert the engine block heater into the cylinder block. Take the outer spacer washer (4), t=32 mm / 1 1/4", and the screw. Insert the screw through the outer spacer washer, into the hole in the tensioner and through the inner spacer washer
- Carefully move the engine block heater into position using the screw in the tensioner until the threaded cast protrusion (3) in the cylinder block is found
- Finger tighten the screw
- Take the extension cable and the heat shield from the kit. Thread the heat shield onto the extension cable
- Lubricate the O-ring on the extension cable. Use low temperature grease, (P/N 1161417-9).

Illustration B




- Take a locking sleeve from the kit. Connect the extension lead to the engine block heater. Press the locking sleeve into place over the joint
- Pull the heat shield all the way up to the engine block heater so that the cable splice and the plastic surround are completely covered.

Note! Ensure that the heat shield covers the entire joint towards the engine.

- Secure the heat shield around the cable to the engine block heater. Use a grey, heat resistant tie strap and clamp the bottom edge of the heat shield
- Tighten the engine block heater. Tighten to 16 Nm (12 lbf. ft.).

Applies to the S80 with six cylinders, naturally aspirated engines and automatic gearboxes, manufactured after week 35, 2001
- Remove the old gaskets between the manifold and engine
- Clean the gasket faces carefully. Use a razor blade or gasket scraper
- Install new gaskets between the manifold and engine (P/N 271734)
- Lubricate the threads on the studs. Use paste (P/N 1161408)
- Install the manifold. Use new nuts (P/N 948645). Tighten the nuts. Tighten to 25 Nm (19 lbf.ft.)
- Install the heat deflector plate. Do not tighten yet
- Lubricate the threads on the heated oxygen sensors (HO2S). Use paste (P/N 1161408).

Note! Do not mix up the heated oxygen sensors (HO2S).

- Install the heated oxygen sensors (HO2S). Tighten to 45 Nm (34 lbf.ft.)
- Tighten the heat deflector plate
- Remove the old gaskets on the flanges to the manifolds
- Install the new gaskets (P/N 8627203) on the flanges to the manifolds
- Connect the exhaust pipes to the manifolds. Lubricate the threads. Use new nuts (P/N 945408)
- Tighten the nuts. Tighten to 25 Nm (19 lbf. ft.)
- Move the side impact protection member into place. Press the brake pipe into place in its clip. Press the cable to the left rear heated oxygen sensor (HO2S) into place in the side impact protection member
- Tighten the screws for the side impact protection member. Tighten to 25 Nm (19 lbf.ft.).

Applies when only installing the engine block heater




- Remove the existing nut from the steering gear
- Install the mounting bracket for the junction switch and cables
- Install the lock nut from the kit. Tighten to 48 Nm (36 lbf. ft.)
- Secure the first tie strap on the power steering pipe. If there is no servo coolant pipe; drill out the first hole to a diameter of 6.5 mm (1/4"). Secure the tie strap as normal.

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

Applies when installing the engine block heater and passenger compartment socket together




- Install the Y connector on the bracket. Use the screw and the nut from the kit
- Lubricate the O-rings. Use low temperature grease, (P/ N 1161427)
- Connect the wiring from the front engine block heater socket (1), the passenger compartment socket (3) and the engine block heater (2) to the Y-connector
- Tighten the Y connector and the bracket on the steering gear. Tighten to 48 Nm (36 lbf. ft).

Points 43-45 apply to all models




- Route the cable from the bumper to the cable from the engine block heater. See the illustration
- Clamp the cable in the existing holes and to the oil cooler pipe. Use tie straps
- Connect the cable from the bumper to the cable from the engine block heater. Alternatively connect the cable from the bumper to the Y connector.

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




- Install the locking sleeves over all the connectors and cable splices on the wiring. Ensure that these are correctly installed.

- Reinstall the air baffles and the splash guard. See points 11 and 12
- Tighten the splash guard screws. Tighten to 25 Nm (19 lbf. ft)
- Clamp the engine heater cable in the mounting on the left-hand side of the air baffle.

Applies to cars with six cylinder, naturally aspirated engines
- Reinstall the hose for the air preheating
- Reinstall the bracket and cable for the right-hand heated oxygen sensor (HO2S).

Applies to cars with six cylinder engines
- Reinstall the engine stabilizer brace across the engine. See point 21
- Tighten the screws. Tighten to 80 Nm (60 lbf.ft.). Tighten the screw and the nut. Tighten to 60 Nm (43 lbf.ft.)
- Secure the servo hose at the engine stabilizer brace. Use a tie strap from the kit.

Applies to cars with TDI engines and immersion heaters
- Top up the coolant. Test run the engine. Check for any leakage.

Applies to cars with six cylinder naturally aspirated engines, manufactured after week 35, 2001
- Test run the engine. Check for exhaust leaks.