Electric engine block heater 230V (1)

• Remove the rubber moulding from the bumper. Pry up the moulding at one corner using a weatherstrip tool. Then pull off the entire moulding.

• Cut a hole in the moulding according to the marking (1) on the reverse of the moulding. Use a utility knife or similar. Cut so that there is a safety margin. Finely adjust the hole using a file.

Примечание: When cutting along the upper horizontal line, angle the knife towards the upper edge of the moulding. Guide the knife along the moulding. This is so that the cut is not positioned in the centre of the curvature of the moulding.

• Reinstall the rubber moulding
• Install the protective cover (1) for the front engine block heater socket in the moulding
• Mark out the hole in the bumper cover (2) using a 29 mm (1 1/8") diameter hole saw and the central drill bit
• Remove the protective cover. Drill out the hole using a 29 mm (1 1/8") hole saw
• Remove any swarf
• Reinstall the splash guard.

• Raise the car.

Remove:

• the screw (1) from the left air baffle (2)
• the left-hand air baffle by pulling the air baffle backwards
• the right-hand air baffle in the same way.

Remove:

• the air baffle (2). First slacken off the screws (1). Press up the catches (5). Move the air baffle downwards and backwards
• the engine cover (4) by slackening off the screws (3).

Installing the front engine block heater socket

• Thread the cable for the front engine block heater socket through the protective cover (1) and the bumper cover (2)
• Install the plastic nut (3) from the kit on the front engine block heater socket. Tighten the plastic nut. The cover must be horizontal and is opened forwards.

Подсказка: The nut is difficult to access. Tighten using the cable instead.

• Route the wiring down along the left-hand side of the side member.

• Remove the left-hand headlamp by pulling up the two cotter pins and then carefully pulling the headlamp forwards.

• Carefully pry up the catch on the connector for the headlamp using a screwdriver
• Pull up the catch completely, disconnect the connector. Place the headlamp to one side.

• Carefully pry up the left-hand grille on the bumper up using a weatherstrip tool. Remove the grille.

• Measure for drilling out the hole for the front engine block heater socket as illustrated
• Drill out the hole. Use a 3 mm (1/8”) diameter drill bit
• Drill out the hole. Use a 29 mm (1 1/8”) diameter hole saw
• Remove any swarf.

• Cut the tabs (1) using a utility knife so that they are at the same height. This ensures a flat surface for the plastic nut for the front engine block heater socket to be tightened against.

• Make a cut out for the connector for the front engine block heater socket in the second hole from the left in the left-hand bumper grille
• Smooth off the edges
• Press the grille into the bumper.

Illustration A

• Take the front engine block heater socket, blind cover plug and plastic nut from the kit
• Install the blind cover plug on the front engine block heater socket connector. Turn the connector so that the cover opens on the left-hand side of the car as illustrated.

Illustration B

• Install the plastic nut
• Tighten the plastic nut properly
• Route the cable down along the outside of the left-hand side member.

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

• Drill a hole at the front edge/lower edge of the side member using a 4 mm (5/32") diameter drill bit
• Rust-proof and secure the ground lead using the included 4.8 mm (3/16") diameter flanged screw and toothed washer (under the screw head).

Примечание: Connect the ground lead to the side member, not to the sub-frame.
- Secure the ground lead excess using a tie strap.

Does not apply to diesel models

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

Does not apply to diesel models

• Grease the O-ring on the connector for the heater joining cable. Use low temperature grease, (P/N 1161417-9).

Примечание: Do not get any grease on the surfaces of the connector.

Applies to cars with five cylinder engines and a stay for the turbocharger (TC)

• Remove the stay.

Applies to cars with five cylinder engines and a stay for the turbocharger (TC)

• Clean the area where the heater will be positioned. This ensures optimal heat conduction to the cylinder block. Also clean the internal threads
• Install the heater on the cylinder block, as illustrated.

Подсказка: To facilitate installing the heater on the cylinder block, first secure the tensioner (2) at the heater using a piece of butyl tape. Then also secure the spacer sleeves (1 and 4) on each side of the tensioner using small pieces of butyl tape.
- 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.)
- Thread the supplied radiant heat protection on the supplied cable. Connect the cable to the heater.

Illustration B applies to cars without a stay for the turbocharger (TC)

• Clean the area where the heater will be positioned. This ensures optimal heat conduction to the cylinder block. Also clean the internal threads
• Install the heater on the cylinder block, as illustrated.

Подсказка: To facilitate installing the heater on the cylinder block, first secure the tensioner (2) at the heater using a piece of butyl tape. Then also secure the spacer sleeves (1) on the reverse of the tensioner using a small piece of butyl tape.
- 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), (32 mm (1 1/4”)) on the outside of the tensioner (2)
- Screw the heater into place. Use the screw from the kit. Tighten to 16 Nm (12 lbf. ft.)
- Thread the supplied radiant heat protection on the supplied cable. Connect the cable to the heater.

Does not apply to diesel models

• Pull the radiated heat shield all the way up to the engine block heater so that the cable splice and the plastic surround are completely covered.

Примечание: It is important that the radiated heat shield covers the cable entire splice towards the engine.

• Secure the radiated heat shield around the cable to the engine block heater. Use a grey heat resistant tie strap in the lower edge of the radiant heat shield.

Applies only 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.

Applies only to TDI engines and immersion heaters

• Pull out the core plug using an extractor.

Applies only to TDI engines and immersion heaters

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

• Remove the existing nut from the steering gear
• Install the bracket for the attachment of the junction switch and cables
• Install the new lock nut supplied. Tighten to 48 Nm (36 lbf. ft.).

Applies if the engine block heater and passenger compartment connector socket must are to be mounted at the same time

• Install the junction connector on the bracket using the screw and nut from the kit
• Lubricate the O-rings using low temperature grease, (P/N 1161417-9) (see point 15)
• Connect the wiring from the front engine block heater socket (1), the passenger compartment socket (2) and the engine block heater (3) to the junction connector
• Tighten the junction connector to the bracket for the steering gear.

• Press the four tie-straps (from the kit) into the holes on the inside of the sub-frame
• Route the cable from the front engine block heater socket above the front edge of the sub-frame and backwards to the cable from the engine block heater
• Secure the cable in the installed tie straps
• Lubricate the O-rings on the connector using low temperature grease, (P/N 1161417-9) (see point 15).

• Route the cable from the engine block heater over the oil cooler to the bracket previously installed
• Take the double clamp (1) from the kit. Secure the cable at the left-hand hose on the oil cooler and at the right-hand pipe using a tie-strap (2) from the kit as illustrated.

• Connect the cable from the front engine block heater socket to the cable from the engine block heater. Alternatively connect the cable to the junction connector
• Press the locking sleeves (from the kit) over the cable splices
• Press one clamp (from the kit) into the hole on the previously installed bracket
• Secure the cable at the bracket as illustrated.

Примечание: 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.

Applies to the S60 and V70 (00-)

• Reinstall the centre air baffle and engine splash guard. Tighten the screws for engine splash guard. Tighten to 25 Nm (19 lbf.ft)
• Clamp the engine heater cable in the mounting on the left-hand side of the air baffle
• Reinstall the air baffle on the right and left-hand sides.

Applies to the XC90

• Reinstall the engine splash guard. Tighten the screws for engine splash guard. Tighten to 25 Nm (19 lbf.ft)
• Connect and reinstall the headlamp.