Electric Engine Block Heater, 110V

Electric engine block heater, 5-cyl. 110V































INTRODUCTION
- NOTE! Read through the whole installation instruction before starting the work.
- The illustrations display the procedure in order of operation. The order of operation is repeated in the text section.






Electric engine block heater, 5-cyl. 110V

Preparations, applies to the S60/V70/S80

Image A applies to the S60 and V70





Image B applies to the S80 up to and including model year -2003 (CH -334999)




- Press in the centers of the six clips until a click is heard. Remove the clips.
- Pull the top edge of the front forward.
- Insert a hand inside and press the four catches that are evenly distributed along the upper edge up/down. Use a plastic weatherstrip tool.
- Pull the front grille at the top until the catches release.

Image A applies to the S60 and V70




- Take a weatherstrip tool and insert it between the front grille and bumper cover, and carefully prize the front grille away along the whole of the bottom edge. It is secured with three clips.

Image B applies to the S80 up to and including model year -2003 (CH -334999)




- Depress the three catches at the lower edge of the front grille using a small screwdriver or similar, remove the front grille.

Steps 3-6 apply to the S80 from model year 2003- (CH 335000-)




- Remove the nut and wiper arm for headlamp washing.
- Detach the hose for washing at the existing joint.
- Carefully pry off the parking lamp at the front edge. Use a plastic weatherstrip tool.
- Detach the connector and place the position lamp to one side.
- Repeat the operation on the other side.




- Remove the molding under the headlamp. Use a weatherstrip tool.

Note! Do not damage the paintwork.

- Repeat the operation on the other side.




- Press in the center of the clips at the top edge of the bumper cover and remove them.
- Remove the covers in front of the bumper cover's lower screws.
- Remove the screws in the bumper cover.




- Press the center of the clip at the lower edge/side of the bumper and remove it.
- Remove the screw in the rear/top edge of the bumper cover.
- Repeat the operation on the other side.
- Carefully pull away the end face of the bumper cover from the body. It is fitted with four catches on the inside in the top edge and two in the bottom edge.
- Repeat the operation on the other side.
- Pull the bumper cover forwards, detach the connectors for the fog lamps if fitted.

Assembling the front intake





Applies to the V70, and S80 up to and including model year -2003 (CH -334999)
- Cut off the shaded sections on the mounting plates as illustrated in figures A and C.

Applies to the S80 from model year 2003- (CH 335000-)
- Cut of the shaded section on the mounting plate as illustrated in figure B.

Applies to the XC90 up to and including model year -2006 (CH-327999), and S60/V70/S80
- Assemble the front intake according to figure D.

Installing the front intake, applies to the XC90

Steps 8 - 10 applies to the XC90 up to and including model year -2006 (CH-327999)




- Guide the front socket's cable in through the center hole, next furthest to the left in the grille.




- Take a screw, washer and attaching plate from the kit and install the front socket. Push it as far to the left as possible and tighten it.
- Pull the cable to the left, in through the rubber seal on the left-hand side of the radiator, continue down by the left front side, on the right-hand side.




- Remove the engine splash guard (1) by first removing the screws (2).

Steps 11- 23 apply to the XC90 from and including model year 2007- (CH 328000-)




- Clean the surface where the front engine block heater socket will be secured.




- Drill a hole for the guide to the front engine block heater socket's mounting plate.
- File down the edges of the holes.




- Drill a hole for the tie strap for the front engine block heater socket's cable.
- File down the edges of the holes.




- Cut-off all shaded sections on the mounting plate so that only the cylinder shaped section remains.




- Drill a -5 mm (3/16 ") diameter hole in the mounting plate.
- File down the edges of the holes.




- Assemble the front intake as illustrated. The mounting plate (A) must not be used.




- Install the front engine block heater socket with the guide pin in the large hole.
- Route the cable in so that it runs down on the inside of the left-hand bracket for the skid plate.
- Align the front engine block heater socket so that the long sides of the mounting plate are parallel with the edges of the surface into which the mounting plate shall be screwed.
- Mark out for drilling the hole for the screw for the mounting plate.




- Drill a hole with a - 5 mm (3/16 ") diameter drill bit for the screw for securing the front engine block heater socket's mounting plate.




- Secure the front engine block heater socket with a screw and nut in the drilled hole and tighten.




- Secure the tie strap in the hole around the front engine block heater socket's cable.
- Fold in the connector so that the cable adopts the correct length in the tie strap before it is tightened.
- Tighten the tie strap.




- Clamp the cable in at the pipe for the air conditioning using a double tie strap.




- Remove the engine splash guard.




- Pull the cable from the front intake over the skid plate, above the inside of the front left-hand side corner of the subframe, and down to the inside of the left-hand side of the subframe.
- Take the tie strap equipped with clip and press it into the hole on the top of the left-hand bracket for the skid plate.
- Tighten the cable with the tie-strap.

Installing the front intake, applies to the S60/V70/S80

Image A applies to the S60 and XC70




- Insert the cable through the next upper hole along to the left in the front grille. The cable must be inserted inside the weatherstrip at the edge of the front grille.
- Reinstall the front intake and tighten it with the screw.

Image B and C apply to the V70, and S80 up to and including model year -2003 (CH -334999)








- Place the front grille with the front facing upwards on a table, as illustrated.
- Place a weight on one end of the front grille so that it remains still.
- Take the electrical cable from the kit.
- Take a plastic weatherstrip tool or similar and insert it down into the fourth compartment in the left-hand side of the front grille, and turn the tool carefully so that the plates in the front grilled are separated from each other. Turn so that the cable's connector can be inserted through the front grille.
- Carry out the same procedure with the cable's black joint section, but do not bend the plates more than the join section can pass between them as this can damage the plates.

Image D applies to the V70, and S80 up to and including model year -2003 (CH -334999)




- Install the front intake 50 mm (2") from the upper edge of the front grille, and tighten using the screw.

Applies to the S60, V70, and S80 up to and including model year -2003 (CH -334999)
- Reinstall the front grille and clips at the upper edge on the front.

Steps 26-27 apply to the S80 from model year 2003- (CH 335000-)




- Guide the front intake's cable in through the uppermost hole in row, next furthest to the left in the grille.
- Take screws and mounting plate from the kit. Install the front intake and slide it to the left as far as possible. Tighten.




- Insert the cable from the front intake on the upper side and rear side of the collision member on the left-hand side of the radiator and allow them to hang down.
- Reinstall the bumper cover to the body using screws and clips. Align the length of the cable by the front edge/left side of the rubber seal.
- Tighten the four M8 screws to 24 Nm (18 lbf.ft.) and reinstall the covers.

Steps 28 - 30 apply to the S60, V70 and S80




- Raise the car.

Applies to cars with side air baffles
- Remove the screw (1) from the left-hand air baffle (2), and remove the air baffle by pulling it backwards.
- Carry out the same procedure on the right-hand air baffle.





Remove:
- the air baffle (2) by undoing the screws (1), pressing up the catches (5) and moving the air baffle down and back.
- the splash guard (4) by undoing the screws (3).

- Move the cable from the front grille down to the left, passing the radiator and under the car to the air pump. (Also see image in point 30).

Installing, engine block heater

Applies to models




- Pull the cable above the subframe and on the inside of its left front mounting, along the left-hand side and up towards the engine.
- Clamp the cable using tie straps in the existing holes and with double clamps at pipes on the oil cooler.

Caution! Do not clamp the drive axle, and ensure that the cable does not chafe against sharp edges.





Applies to cars with T stay, as illustrated
- Remove the stay.





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

Caution! The heat conducting paste must be applied as illustrated. This is to prevent damage from overheating.

Image A applies to cars with T stay, as illustrated





Image B applies to cars without T stay




- Clean the area where the heater is to be installed. This ensures optimal heat conduction to the cylinder block. Also clean the internal threads.
- Connect the cable supplied to the heater.
- Install the heater on the engine block, as illustrated.
- Install spacer washer (1) (t=10 mm (25/64")) between the mounting bracket (2) and mounting hole (3) in the engine block. The outer spacer washer(4) (t=32 mm (1 1/4")) is inserted between the mounting bracket (2) and the T stay, if applicable.
- Tighten the heater using the screws from the kit. Tighten to 16 Nm (12 lbf.ft.).

Applies to cars with stay for the turbocharger from model year 2005-

Note!
- S60 CH 425000-
- V70 CH 459000-
- XC70 CH 173000-
- S80 CH 390000-
- XC90 CH 134000-

Illustration A




- Knock off the spacer (1) from the stay. Grind off the welds if the spacer is secured too tightly.

Illustration B




- Carefully clean the surface where the heater is to be located to provide good heat conduction to the engine block. Also clean the internal threads.

Hint: To facilitate the installation of the heater on the engine block, first secure the tensioner (2) by the heater using a small piece of butyl tape and then also secure the spacer sleeve (1) on the rear side of the tensioner using a small piece of butyl tape.

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

- Install space washer (1)(t=10 mm (25/64")) between tensioner (2) and the mounting in the engine block (3). Install the outer spacer washer (4) (t=32 mm (1 1/4")) on the outside of the bracket.
- Thread through the long screw (5) so that everything is held together.

Illustration C




- Thread the heater and the tensioner. Install the turbocharger stay and screw using the three screws as follows:
- Screw the turbocharger stay into place through the tensioner in the mounting in the engine block, with the long screw (1).
- Screw the turbocharger stay in the turbocharger with the short screw (2) and into the other mounting in the engine block with the screw (3).
- Tighten the screws to 16 Nm (12 lbf.ft.).
- Take the radiation protection and cable from the kit. Thread the radiation protection onto the cable and connect the cable to the heater
- Install the locking sleeve on the heater's connector.





Install:
- air baffle
- the splash guard. Tighten the screws to 25 Nm (18.5 lbf.ft.).
- the decal from the kit.