Electric engine heater, 230 V, 4-cyl, 2.0

Applies to the S80

• Use isopropanol to clean the bumper cover where the cutting template for the front engine block heater socket is to be secured.
• Wipe dry.

• Take the template from the kit and cut it along the dotted lines.

• Remove the protective backing tape from the template and secure the template edge to edge with the front edge of the front wing and embossing in the bumper cover as illustrated.

• Using a sharp knife, first make a thin cut along the edges of the inside of the template. This provides a groove to follow. Then carefully cut the bumper cover.

Примечание: Cut carefully. It is easy to slip with the knife and move outside the template.
- Remove the template and tape pieces.
- Install the protective cover for the front engine block heater socket from the kit. Check that it aligns. Adjust the hole using a knife or file as necessary.
- Smooth off the hole edges. Remove any swarf.

Applies to the V70

• Find the template for the front intake in the installation instructions. Cut it out following the dotted lines.

Примечание: Check the scale.

• Attach the template using tape edge to edge with front edge of the front wing and the embossing in the bumper cover as illustrated.

• Take a sharp knife. First make a thin cut along the edges of the inside of the template. This provides a groove to follow. Then cut carefully out of the bumper cover.

Примечание: Cut carefully. It is easy to slip with the knife and move outside the template.
- Remove the template.
- Install the protective cover for the front engine block heater socket from the kit. Check that it aligns. Adjust the hole using a knife or file as necessary.
- Smooth off the hole edges. Remove any swarf.

Applies to all models

• Press the protective cover (from the kit) into place in the hole cut in the bumper cover.
• Take the cable for the front engine block heater socket with ground lead from the kit and thread them through the protective cover.

Illustrations A and B

• Install the attaching brace and nut from the kit.
• Rotate the connector for the front engine block heater socket so that the cover opens backwards (Illustration B).
• Plug the electrical connector into the front engine block heater socket. Use the connector as a counterhold when tightening.
• Tighten the front engine block heater socket to the bumper shell.
• Press the cable into the holder on the washer fluid reservoir.
• Remove the cover on the radiator expansion tank.

Illustrations A and B

• Route the cable with the ground cable from the front engine block heater socket in front of the left-hand front mounting for the subframe and down on the inside of the subframe.

• Drill a Ø 4mm (Ø 5/32 ") hole for the front intake grounding on the underside of the left front side member as illustrated.
• Deburr the hole edges, remove the drill swarf and apply rustproofing agent.
• Take a screw and toothed washer from the kit. Tighten the ground cable.

• Drain the coolant.
• Tighten the nipple after draining.

• Disconnect the connectors for the heated oxygen sensors.

• Slacken the screws for the radiated heat shield above the catalytic converter. Move the radiated heat shield to the right-hand side. Do not damage the cable for the heated oxygen senor and thread through it through the hole if necessary.

• Depress the catches at the sides of the vacuum pipe connection for the valve cover, and pull out.

• Remove the air filter by first detaching the hose clamp. Pull it up at the rear edge and pull it out from the inlet pipe at the front edge. It is secured by three mountings in the body. Do not damage the surrounding components.

• Remove the vacuum valve with pipe from the holder.

• Move the vacuum pipe to one side and secure it at the heater hose.

• Place a container under the engine, a large amount of coolant remains in the engine.
• Remove the plug from the engine block, use tool P/N.9997362 and long extension. Carry out work from underneath. Do not damage the heated oxygen sensor with cable on the left-hand side of the catalytic converter.

• Take the heater from the kit and apply thread sealant to the threads.
• Screw the heater into place from above and tighten properly. Use wrench P/N 9997158.

• Take the cable splice from the kit. Route it above the transmission along the thick wiring harness and towards the location for the heater.

• Take the radiation shield from the kit and thread it on the cable.

• Lubricate the O-ring on the contact on the routed cable using low temperature grease.

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

• Press the cable securely into the heater's contact. Press a locking sleeve from the kit over the splice.

• Pull the radiation shield up so that it fully covers the spliced contact on the heater.
• Take a grey cable tie from the kit and tighten the radiation shield for the contact on the heater.

• Take two double cable ties from the kit. Tighten the cable at the two wiring harnesses.

• Take the clip with tie strap for a Ø 6.5 mm (1/4 ") hole and press it into the left hole on the inside of the upper edge of the subframe.

• Take three clips from the kit and press onto the subframe's upper/front edge and at the left front edge.
• Position the two clips that are nearest the tie strap fitted previously following the measurements specified in the illustration.

• Lubricate the O-ring on the contact on the cable from the front intake using low temperature grease.

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

Illustration A

• Connect the extension cable of the engine heater with the cable from the front intake. Press the connectors together and press a locking sleeve from the kit over the splice.

Illustration B

• Clamp the cable splice (1) to the inside of the subframe using the tie strap and press the cable into the clips.

Illustration C

Applies when fitting passenger compartment connector at the same time

• If the passenger compartment connector is to be installed at the same time, install the junction connector now. Lubricate the O-rings on the contacts as previously.
• Connect:

Illustration D

Applies when fitting passenger compartment connector at the same time

• Insert the junction connector in the space in the subframe. Secure the junction connector by fastening the cable tie through the rear hole of the connector.

If the passenger compartment connector socket is to be installed at the same time then install the junction connector now in accordance with illustration C and D, and connect the cables to it.

• Fill with coolant and warm up the engine. Bleed the cooling system and check for leaks. Top up the cooling system as necessary.