Electric Engine Block Heater, 110V

Electric engine block heater, 110V, 6-cyl































INTRODUCTION
- Read through all of the instructions before starting installation.
- Notifications and warning texts are for your safety and to minimize 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.






Electric engine block heater, 110V, 6-cyl





- 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 away the three pins on the front engine block heater socket's mounting plate.





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






Illustration A, B, C and D
- Assemble the front engine block heater socket with the parts from the kit as illustrated.

















- 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 cover on the cooling system expansion tank.





- Remove the engine splash guard.





- Detach the nipple and drain the coolant.
- Retighten the nipple after the coolant has been drained.





- Rotate the catch on the coolant pipe that runs to thermostat housing anticlockwise, pull the hose out and drain the remaining coolant.





- Detach the hose clamp on the hose to the thermostat housing inside the intake manifold and remove the hose.





- Cut the removed hose as illustrated. First cut to a dimension of 52 mm (1 1/16 ").
- Discard the small cut-off hose bend.





- Reinstall the longer of the hose sections onto the thermostat housing's connection and tighten the hose clamp. Make sure that the cut-out in the upper hose-end fits into the corresponding pin in the pipe connection in the thermostat housing.





- Remove the short hose-end and press it on the pipe that runs to the thermostat housing. Make sure that the cut-out in the hose connection is turned down and fits into the corresponding pin in the pipe connection.
- Rotate the catch on the pipe clockwise against the stop.
- Take a hose clamp from the kit and install it on the hose-end.





- Take the engine block heater, bracket, rubber coated clamp and screw from the kit and assemble them as illustrated.
- Do not tighten the screw yet.





- Take the hose clamp from the kit and fit it onto the engine block heater's upper connection.





- Position the engine block heater with bracket in the front edge of the oil sump and connect both hose-ends to the engine block heater's connections.
- Take a screw from the kit and tighten the bracket with engine block heater into the existing hole in the oil sump.

Note! The screw is self-tapping so inserting it may be slow. Make sure that the screw is centered straight into the hole, so that the screw head is flat against the bracket.





- Now adjust the engine block heater in the rubber coated clamp so that the hoses are properly fitted on the engine block heater's connections.
- Tighten the screw to the rubber coated clamp.
- Tighten the hose clamps to the engine block heater.





- Take five double tie straps from the kit and secure them on the pipe and hose to the thermostat housing as well as the lower hose to the radiator.
- Check that the cable does not chafe against sharp edges or moving parts in the engine compartment.

Caution! Do not clamp the cable directly to brake pipes, fuel lines, AC pipes or pipes to the power steering.





- Take a tie strap equipped with clip and press it into the hole on the top of the left-hand bracket for the skid plate.





- Grease in the O-ring on the connector on the cable to the front engine block heater socket, use low temperature grease P/N 1161427.

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





- Connect the cable in the engine block heater and press it in firmly.
- Press a locking sleeve from the kit over the cable splice.





- Clamp the joint cable from the engine block heater into the recently installed tie straps. Clamp up all excess cable around the tie strap on the top of the skid plate bracket.
- If necessary, use another tie strap for clamping the cable behind the skid plate.

- Fill with coolant, run the engine to operating temperature, bleed the cooling system and check that there are no leaks.
- Top up the cooling system as required.
- Reinstall the engine splash guard and torque tighten the screws to 25 Nm (18.5 lbf.ft.).