Part 2

Electrical engine block heater, 110V, 5 cyl 2WD (Continued)

Installing the front engine block heater socket.

Steps 29-39 do not apply to C30




- Cut out a hole in the bumper shell grille.




- File away any irregularities.




- Take the cable harness and thread on the protective cap's eyelet.




- Install the front engine block heater socket's connector in the mounting.




- Lift the mountings at the back in order to lock the connector.




- Install the mounting plate in the connector with the screw and nut. Do not tighten too hard, it must be possible to guide the connector into the mounting.




- Cut away the three rectangular studs on the mounting plate.




- Route the cable harness through the hole in the grille so that the front engine block heater socket's connector is in contact with the grille.




- Cut away any protrusions on the grille where the spacer washer shall be located.
- Tighten in the connector using a Torx screw with integrated washer (L=14 mm), and a spacer washer from the kit.




- Check the function. Install the protective cap on the connector.





Reinstall:
- the air baffle
- the bumper. Make sure that the air baffle is positioned correctly in its mounting against the bumper. Press on so that the catches under the headlamps attach.
- the five clips and the screws in the top edge.
- the connectors to the fog lamps.

Note! Installation of the bumper is facilitated if carried out by two people.

Installing the front intake (C30)

Steps 40-46 only apply to the C30




- Remove the left front wheel.
- Remove the screws and the engine splash guard.




- Drill a - 4.5 mm (11/64 ") in the left-hand fog light panel for the hole to fasten the front intake mounting plate. Use a 5 mm (13/64 ") drill stop.

Note! Only drill through the panel. Do not drill through the bumper shell on the inside.




- Remove the panel of the left-hand fog light by using a weatherstrip tool to carefully press in the catches on the top edge of the panel and then pull it loose. The panel is held in place with six catches. Also press the catches on the inside to facilitate removal.




- File or cut out the top edge of the panel to make room for the front intake cable. See diagram.
- Even off the edges.




- Use a hole saw to drill a - 20 mm (25/32 ") for the grommet of the front intake cable. Use a 10 mm (25/64 ") drill stop.





Illustration A, B, C and D
- Take the front intake components from the kit and assemble them as illustrated.


















Illustrations A and B
- Position the front intake in the panel and fasten it with the screw and washer.
- Insert the cable through the hole in the bumper shell.
- Refit the panel with front intake.





Cable routing, applies to all car models




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

Illustration A




- It may be necessary to detach the air baffle on the underside of the bumper shell to make it possible to fit the cable between the front grille's left side end plate and the seal in front of the radiator on the S40/V50 and C70.
- Route the front intake cable through at the seal at the lower front grille's left-hand side end plate (S40/V50 and C70) / from the fog light panel (C30). Route it on the top of the radiator's left bracket (1) and up to the bottom edge of the side member. Clamp it at the bracket (1) using a tie strap from the kit. Route it along the bottom edge of the front member and over the drive shaft. Route the cable up a bit in the engine compartment.

Illustration B




- Press the cable into the previously installed clips.
- Reinstall the air baffle in the bumper shell and to its rear mounting in the bracket in the lower edge of the radiator.
- Reconnect the connectors for the fog lamps if applicable.
- Press the ends of the bumper shell into place on the body.




- Position the cable as illustrated, and clamp it in at the top of the strut using a tie strap from the kit. Route it up to the top of the engine compartment.




- 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.

Illustration A




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

Illustration B




- Clamp in the cable, from the top of the engine compartment and down, using a tie strap.

Note! The cable must not be clamped directly to AC, fuel or brake pipes.




- Clamp the cable from the front engine block heater socket in at the top of the strut using a tie strap from the kit.




- Grease the O-ring on the front engine block heater socket's connector using low temperature grease part no. 1161417.

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

Installing the engine block heater




- Remove the cover on the radiator expansion tank.
- Unscrew the drain nipple in the radiator pipe above the oil cooler in front of the right drive shaft. Drain the coolant.




- Detach the hose clamps of the left oil cooler hose and remove the hose.
- Put the hose to the side.




- 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 centered straight into the holes, so that the screw heads are flat against the bracket.




- Take the heater, rubber-clad clamp and bolt from the kit. Fasten the heater with the clamp. The connections should point straight back.




- Take the long hose and two hose clips from the kit. Connect the hose between the radiator pipe and upper heater socket.
- Tighten the hose clips.




- Take the remaining hose and two hose clamps from the kit. Connect the hose between the oil cooler and the lower outlet on the heater. The end with the long straight section must be connected to the oil cooler.
- Tighten the hose clips.




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




- 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.




- 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.

Illustration A applies to cars without turbocharger




On cars with petrol engine without turbo, route the cable with radiation shield below the power steering hoses/pipes.
- Fit a double tie strap to the two steering gear pipes and the cable with radiation shield.
- Fit the double tie strap over the hoses' press sleeves.

Illustration B applies to cars with turbocharger




On cars with petrol engine and turbo, route the cable with radiation shield under the power steering hoses/pipes and under the turbo pipe.
- Fit a double tie strap to turbocharger pipe and the cable with radiation shield.
- Fit a double tie strap to the cable and the left power steering pipe.

- Reinstall the left-hand fender liner. Tighten the fender liner to the left-hand side member.
- Tighten the two fender liners to the bumper shell on the right and left-hand sides.
- Refit the covers to the nozzles for the headlamp high-pressure washers.
- Fill with coolant, run the engine to operating temperature, bleed the cooling system and check that there are no leaks.
- Reinstall the engine splash guard.
- Remount the front wheel and tighten the lug bolts to 90 Nm (66 ftlb.).