V70 (00-08) / V70 XC (01-) / XC70 (-07) / XC90 V70 (00

Installation instructions, accessories - Electric engine block heater
Volvo Car Corporation Göteborg, Sweden
V70 (00-08) / V70 XC (01-) / XC70 (-07) / XC90
Section Group Weight(Kg/Pounds) Year
8
876 2 / 4.3
Month
2005 11
V70 (00-08) 2001 D5244T, V70 (00-08) 2002 D5244T, V70 (00-08) 2002 D5244T2, V70 (00-08) 2003 D5244T, V70 (00-08) 2003 D5244T2, V70
(00-08) 2004 D5244T, V70 (00-08) 2004 D5244T2, V70 (00-08) 2004 D5244T3, V70 (00-08) 2005 D5244T, V70 (00-08) 2005 D5244T2, V70 (0008) 2005 D5244T3, V70 (00-08) 2006 D5244T, V70 (00-08) 2006 D5244T2, V70 (00-08) 2006 D5244T4, V70 (00-08) 2006 D5244T5, V70 (00-08)
2006 D5244T6, V70 (00-08) 2006 D5244T7, V70 (00-08) 2007 D5244T4, V70 (00-08) 2007 D5244T5, V70 (00-08) 2007 D5244T6, V70 (00-08)
2007 D5244T7, V70 (00-08) 2008 D5244T4, V70 (00-08) 2008 D5244T5, V70 (00-08) 2008 D5244T7, V70 XC (01-) / XC70 (-07) 2003 D5244T, V70
XC (01-) / XC70 (-07) 2004 D5244T, V70 XC (01-) / XC70 (-07) 2005 D5244T, V70 XC (01-) / XC70 (-07) 2006 D5244T, V70 XC (01-) / XC70 (-07)
2006 D5244T4, V70 XC (01-) / XC70 (-07) 2006 D5244T5, V70 XC (01-) / XC70 (-07) 2006 D5244T6, V70 XC (01-) / XC70 (-07) 2006 D5244T7, V70
XC (01-) / XC70 (-07) 2007 D5244T4, XC90 2003 D5244T, XC90 2004 D5244T, XC90 2005 D5244T, XC90 2006 D5244T, XC90 2006 D5244T4, XC90
2007 D5244T4, XC90 2008 D5244T4, XC90 2008 D5244T5, XC90 2009 D5244T4, XC90 2009 D5244T5
IMG-218164
© VolvoCar Corporation, 2005 Printed in Sweden
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Installation instructions, accessories - Electric engine block heater
Volvo Car Corporation Göteborg, Sweden
Required tools
A0000162
A0000163
A0000161
A0000180
A0000172
IMG-218163
IMG-218162
© VolvoCar Corporation, 2005 Printed in Sweden
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Installation instructions, accessories - Electric engine block heater
Volvo Car Corporation Göteborg, Sweden
IMG-218161
IMG-218160
IMG-235281
© VolvoCar Corporation, 2005 Printed in Sweden
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Installation instructions, accessories - Electric engine block heater
Volvo Car Corporation Göteborg, Sweden
IMG-213320
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Installation instructions, accessories - Electric engine block heater
Volvo Car Corporation Göteborg, Sweden
INTRODUCTION
●
NOTE! Read through the entire text before carrying out
any work.
●
The front page gives the date of this edition and the edition it
replaces
●
The second page shows the tools needed for the installation and
the contents of the installation kit
●
The illustrations display the procedure in order of operation. The
order of operation is repeated in the text section
●
Cut out the text page in order to follow the illustrations and text at
the same time.
© VolvoCar Corporation, 2005 Printed in Sweden
Electric engine block heater
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Installation instructions, accessories - Electric engine block heater
Volvo Car Corporation Göteborg, Sweden
Applies to the V70
Preparations
1
●
Measure out the hole for the front socket as illustrated. The measurement
between the centre of the hole and the corner of the headlamp must be 200 mm
(7 7/8"). Measure out the hole's centre so that it is symmetrically located on the
top of the bumper.
●
Pre-drill the hole using a Ø3 mm (1/8") bit.
●
Drill out the hole. Use a Ø30 mm (1 3/16") diameter hole saw.
●
Remove any swarf.
M8601194
Applies to the V70
2
●
Open the drainage holes on both sides of the connector. Use a screwdriver and
press with manual force in the markings.
M3703484
Applies to the V70
3
●
Install the expander nut in the hole, with the guide pin in the guide hole.
●
Route through the cable from the front socket, including the ground cable, from
above and down. Let them hang down.
M8601252
Applies to the V70
Installing the front engine block heater socket
4
●
Connect the cable to the front socket. Press down and turn the cable clockwise
so that the expander nut expands.
●
Align the cable from the front socket so that the hinge points to the headlamp.
Remove the cable.
M8601253
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Installation instructions, accessories - Electric engine block heater
Volvo Car Corporation Göteborg, Sweden
Applies to the XC70
Preparations
5
●
Clean the bumper cover where the two pieces of tape shall be adhered.
●
Install the two pieces of tape for marking the holes for the engine block heater
connector (use narrow tape). One piece of tape is fitted at the rear edge, under
the corner of the indicator lamp, and vertically down. The second piece of tape's
lower edge is fitted along the upper radius of the bumper cover as illustrated.
M8600602
Applies to the XC70
6
M8600603
●
Mark up a rectangle, in accordance with the measurements in the figure, on the
inside of the corner of the point of intersection of the two pieces of tape. The
distance from the tape edges must be 5 mm (13/64").
●
Protect the bumper cover by applying tape to the surface to be cut.
●
Carefully cut out from the bumper cover in accordance with the marking. Use a
utility knife or similar.
●
Smooth off the edges.
Applies to the XC70
Installing the front engine block heater socket
7
●
Remove the pieces of tape.
●
Take the front socket's protective cover (1) from the kit and press it into the
recess. The part of the protective cover where the hole is closer to the edge
must point forward.
●
Mark out the hole in the bracket (2) inside the bumper cover. Use a Ø29 mm (1
1/8") diameter hole saw without central drill bit.
●
Remove the protective cover and drill out with the Ø29 mm (1 1/8") diameter
hole saw.
●
Remove any swarf.
M8600604
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Installation instructions, accessories - Electric engine block heater
Volvo Car Corporation Göteborg, Sweden
Applies to the XC70
8
●
File out a small recess, 4 x 4 mm (5/32" x 5/32"), in the lower edge of the hole in
the protective cover. The hole is designed for the pin on the expander nut, which
is used for tightening the front socket.
●
Reinstall the protective cover.
M8600605
Applies to the XC70
9
●
Open the drainage holes on both sides of the connector. Use a screwdriver and
press with manual force in the markings.
M3703484
Applies to the XC70
10
●
Install the expander nut (1) in the hole.
●
Guide down the enclosed cable (2), including the ground cable, through the hole.
●
Take the connecting cable (3) from the kit. Fit it together with the cable at the
expander nut. Screw clockwise so that the expander nut expands.
●
Remove the connecting cable.
M8600606
Applies to the XC90 up to and including model year -2006
Preparations
11
●
Detach the left-hand headlamp by pulling up the two locking pins and then
carefully pulling away the headlamp forwards.
R3501343
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Installation instructions, accessories - Electric engine block heater
Volvo Car Corporation Göteborg, Sweden
Applies to the XC90 up to and including model year -2006
12
●
Carefully prize up the catch on the connector for the headlamp with a
screwdriver.
●
Pull the catch up completely, detach the connector and place the headlamp to
one side.
●
Remove the left-hand grille from the bumper by carefully prizing it away with a
weatherstrip tool.
●
Measure out for drilling the front socket hole as illustrated.
●
Pre-drill the hole using a Ø3 mm (1/8") bit.
●
Drill out the hole. Use a Ø29 mm (1 1/8") diameter hole saw.
●
Remove any swarf.
●
Take a utility knife and cut out the discs (1) in such a way that they are equally
as high. The plastic nut for the front socket then has a flat surface to be
tightened against.
R3501493
13
R8600944
14
R8600921
15
R8600945
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Installation instructions, accessories - Electric engine block heater
Volvo Car Corporation Göteborg, Sweden
16
●
Saw or cut out for the front socket connector in the second hole from the left in
the left-hand grille of the bumper.
●
Smooth off the edges.
●
Press the grille into the bumper.
R8600920
Installing the front engine block heater socket
Illustration A
17A
●
Take the front socket, protective cover and plastic nut from the kit.
●
Fit the protective cover on the front socket's connector and turn the connector
so that the cover is opened to the left-hand side of the car as illustrated.
Illustration B
●
Install the plastic nut.
●
Tighten the plastic nut firmly. Connect the cable to the front socket for
counterholding when the plastic nut is tightened.
●
Route the cables down along the left-hand side of the left-hand side member.
R8703775
17B
R8703776
Applies to the XC90 from model year 2007Preparations
18
●
Clean the bumper cover where the front engine block heater socket shall be
secured.
IMG-231722
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Installation instructions, accessories - Electric engine block heater
Volvo Car Corporation Göteborg, Sweden
Applies to the XC90 from model year 2007-
19
●
Remove the clip on the panel for the front fog lamp.
IMG-231723
Applies to the XC90 from model year 2007-
20
●
Remove the panel above the front fog lamp by carefully prizing it loose from the
bumper cover using a weatherstrip tool. It is secured all round with catches.
IMG-231725
Applies to the XC90 from model year 2007-
21
●
Cut out according to the existing marking on the inside of the panel for the
protective cover for the front engine block heater socket.
●
Test and cut until the protective cover fits.
IMG-231682
Applies to the XC90 from model year 2007-
22
●
Pre-drill the hole using a Ø3 mm (1/8") bit.
●
Drill a Ø29 mm (1 1/8 ") diameter hole using a hole saw according to the
existing marking in the lower edge of the bumper cover.
Note!
It is important that the hole is drilled right in the centre of the marking in order to
correspond with the hole cut out earlier.
IMG-231726
●
© VolvoCar Corporation, 2005 Printed in Sweden
Even out the hole edges and remove the drill swarf.
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Installation instructions, accessories - Electric engine block heater
Volvo Car Corporation Göteborg, Sweden
Applies to the XC90 from model year 2007-
23
●
Reinstall the front fog lamp panel
IMG-231727
Applies to the XC90 from model year 2007-
24
●
Press the clip into the panel.
IMG-231728
Applies to the XC90 from model year 2007Installing the front engine block heater socket
25
●
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.
IMG-231729
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Installation instructions, accessories - Electric engine block heater
Volvo Car Corporation Göteborg, Sweden
Applies to the XC90 from model year 2007-
26A
Illustration A
Illustration B
●
Install the nut from the kit.
●
Rotate the connector for the front engine block heater socket so that the cover
opens backwards (Illustration B).
●
Tighten the front engine block heater socket to the bumper cover.
●
Plug the electrical connector into the front engine block heater socket. Use the
connector as a counterhold when tightening.
●
Remove the cover on the radiator expansion tank.
IMG-231730
26B
IMG-231731
Applies to the V70 and the XC70
27
●
Raise the car.
●
Remove:
the screw (1) from the left-hand air baffle (2).
●
the left-hand air baffle by pulling it backwards.
●
the right-hand air baffle in the same way.
D2000257
Applies to the V70 and the XC70
28
●
Undo the screws (1) of the centre air baffle (2) and remove it by pressing up the
catches (3).
D2000214
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Installation instructions, accessories - Electric engine block heater
Volvo Car Corporation Göteborg, Sweden
Installing the engine block heater, applies to all car models
29
●
Remove the engine splash guard (1) by first removing the screws (2).
R2000348
Installing the engine block heater, applies to all car models
30
●
Drill a hole in the front/lower edge of the side member with a Ø4 mm (5/32") bit.
●
Apply anti-corrosion agent and secure the ground cable with the enclosed Ø4.8
mm (3/16") flanged screw and toothed washer (under the screw head).
Note!
Connect the ground cable to the side member, not to the subframe.
R8600915
●
Secure excess ground cable with a tie strap.
Installing the engine block heater, applies to all car models
31
●
Open the cap for the radiator's expansion tank.
●
Position a collection container under the engine and open the coolant cock.
●
Drain the coolant and close the cock.
A8701899
Installing the engine block heater, applies to all car models
32
●
Remove the left cooling hose of the oil cooler and put it aside. The kit contains a
new hose.
IMG-218165
© VolvoCar Corporation, 2005 Printed in Sweden
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Installation instructions, accessories - Electric engine block heater
Volvo Car Corporation Göteborg, Sweden
Installing the engine block heater, applies to all car models
33
●
Take a new cooling hose and two hose clips from the kit. Fit the new cooling
hose in the cooling pipe instead of the old one.
●
Fit the hose clips on the cooling hose, but do not tighten them.
IMG-218166
Installing the engine block heater, applies to all car models
34
●
Take the bracket, rubber-clad clamp, two hose clips, heater and pop rivet from
the kit. Assemble them as illustrated.
●
Tighten the hose clip closest to the heater.
IMG-218167
Installing the engine block heater, applies to all car models
35
●
Remove the screw in the right end of the angle gear.
IMG-218168
Installing the engine block heater, applies to all car models
36
●
Position the heater at the rear edge of the oil cooler and fit the hoses on the
heater pipes/pipes in the oil cooler.
●
Secure the heater bracket to the angle gear using the existing screw.
●
Turn the bracket so that its narrow extension touches the front lower screw of
the angle gear.
●
Check that the cooling hoses are properly fitted and that the right hose does not
rub against the top edge of the oil cooler.
●
Tighten all hose clips.
●
Tighten and torque tighten the screw in the angle gear and bracket to 50 Nm (37
lbf.ft.).
IMG-218169
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Installation instructions, accessories - Electric engine block heater
Volvo Car Corporation Göteborg, Sweden
Installing the engine block heater, applies to all car models
37
●
Remove the existing nut from the steering gear.
●
Install the bracket for mounting the branching connector and cables.
●
Install the enclosed lock nut. Tighten to 48 Nm (36 lbf.ft).
D2900051
Installing the engine block heater, applies to all car models
Steps 38 - 40 apply to cars with gearbox AWF21
38
●
Take a clip from the kit and bend aside the front edge of the left front wing liner.
Press the clip onto the edge of the left front corner of the subframe as illustrated.
IMG-218170
Installing the engine block heater, applies to all car models
39
●
Take a clip from the kit. Press it onto the edge of the subframe near the front of
the link arm nuts as illustrated.
IMG-218171
Installing the engine block heater, applies to all car models
40
IMG-218172
© VolvoCar Corporation, 2005 Printed in Sweden
●
Take three tie straps with clip from the kit and press then into the holes on the
inside of the subframe.
●
Route the cable from the front socket to the left front mounting on the subframe.
Press the cable into the first clip (Illustration 29) and route the cable diagonally
down toward the second clip (Illustration 30) and press it into place.
●
Secure the cable in the installed tie straps and route it back to the cable from the
engine block heater. This routing prevents the cable from being pinched between
the subframe and the gearbox.
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Installation instructions, accessories - Electric engine block heater
Volvo Car Corporation Göteborg, Sweden
Installing the engine block heater, applies to all car models
Applies to cars with other gearbox
41
●
Take four tie straps from the kit and press them into the holes on the inside of the
subframe.
●
Route the cable from the front socket above the front edge of the subframe and
back to the cable from the engine block heater.
●
Clamp the cable securely into the fitted tie straps.
R8703667
Installing the engine block heater, applies to all car models
42
●
Take the heater's short jointing cable from the kit. Lubricate the O-ring on the
connector with low temperature grease (part no. 1161417-9).
●
Lubricate the O-ring on the connector of the newly routed cable to the front
socket.
Note!
Do not get any grease on the surfaces of the connector.
D3601932
Installing the engine block heater, applies to all car models
43
●
Connect the jointing cable (1) to the heater's connector.
●
Install the locking sleeve (2) from the kit over the joint between the heater and the
cable.
IMG-218173
Installing the engine block heater, applies to all car models
Applies if engine block heater and passenger compartment connector shall
be fitted at the same time
44
●
Take the branching connector from the kit. Lubricate the O-rings with low
temperature grease (part no. 1161417-9).
●
Fit the branching connector on the bracket with the screw and nut from the kit.
Tighten.
●
Connect the cables from the front socket (1), the passenger compartment socket
(2) and the engine block heater (3) to the branching connector.
●
Press the locking sleeves (4) from the kit over the joints.
IMG-218174
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Installation instructions, accessories - Electric engine block heater
Volvo Car Corporation Göteborg, Sweden
Installing the engine block heater, applies to all car models
Applies if an engine block heater only is to be installed
45
R2900223
●
Connect the cable from the front socket to the cable from the engine block
heater.
●
Take the locking sleeve from the kit and press it over the joint.
●
Take a clamp from the kit and press it into the hole on the previously installed
bracket.
●
Clamp the cable in at the bracket as illustrated.
Caution!
The cable must not be secured to the drive shaft, to the fuel lines, air conditioning
(A/C) pipes or brake pipes. Ensure that the cable is not rubbing against any
sharp edges and that it is not too close to the turbocharger (TC) or exhaust pipe
to prevent damage from radiant heat.
Installing the engine block heater, applies to all car models
Applies to all models
46
●
Take the two attaching clamps (1) from the kit. Use them to secure the cable
from the engine block heater at the servo line pipe (2). This prevents the cable
and pipe chafing against each other.
IMG-218175
47
© VolvoCar Corporation, 2005 Printed in Sweden
Installing the engine block heater, applies to all car models
●
Fill with coolant, drive to normal operating temperature and check for any leaks.
●
Applies V70/XC70
Reinstall the centre air baffle.
●
Reinstall the two air baffles at the sides.
●
Reinstall the engine splash guard. Torque tighten the screws to 25 Nm (18.5
lbf.ft.).
●
Applies to the XC90
Reinstall the engine splash guard. Torque tighten the screws to 25 Nm (18.5
lbf.ft.).
●
Connect the headlamp and reinstall it.
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