Electrical engine block heater 115V (B5204T3, B5204T4, B5204T5)

Illustration A applies to the S60 and the V70

Illustration B applies to the S80 up to and including -2003 (CH -334999)

• Press in the centre of the six clips until a click is heard. Remove the clips
• Pull the top edge of the front panel forwards
• Insert your hand. Press the four catches distributed along the top edge up or down (see the illustration for the relevant model). Use a plastic weatherstrip tool if necessary
• Pull the top edge of the front grille outward until the catches release.

Illustration A applies to the S60 and the V70

• Insert a weatherstrip tool between the front grille and the bumper cover. Carefully pry off the radiator grille along the lower edge. The grille is secured using three clips.

Illustration B applies to the S80 up to and including -2003 (CH -334999)

• Press the three catches down at the lower edge of the front grille using a small screwdriver. Remove the front grille.

Points 3 - 6 apply to the S80 from model year 2003- (CH 335000-)

• Remove the nut. Remove the wiper arm for the headlamp wash / wipe
• Disconnect the hose to the washer at the existing join
• Carefully pry off the parking lamp at the front edge. Use a plastic weatherstrip tool
• Disconnect the connector. Place the parking lamp to one side
• Repeat the operation on the other side.

• Remove the moulding under the headlamp. Use a weatherstrip tool.

Примечание: Do not damage the paint work.
- Repeat the operation on the other side.

• Press in the centre of the clips at the top edge of the bumper cover. Remove the clips
• Remove the covers in front of the lower screws for the bumper cover
• Remove the screws from the bumper cover.

• Press in the centre of the clip in the bottom edge / side of the bumper. Remove the clip
• Remove the screw in the top edge / rear edge of the bumper cover
• Repeat the operation on the other side
• Carefully pull the end of the bumper cover away from the bodywork. The bumper cover is secured with four catches on the inside at the top edge and two at the bottom edge
• Repeat the operation on the other side
• Detach the bumper cover by pulling it forwards. Disconnect the connectors for the fog lamps (if applicable).

Applies to the V70 and S80 up to and including -2003 (CH -334999)

• Cut off the shaded sections on the mounting plates. See illustration A and C.

Applies to the S80 from model year 2003- (CH 335000-)

• Cut off the shaded section of the mounting plate. See illustration B.

Applies to all models

• Assemble the front engine block heater socket. See illustration D. Also see the illustration in point 7 for the S60 and XC70.

Points 8 -10 apply to the XC90

• Insert the cable for the front engine block heater socket through the centre hole, second in on the far left of the grille.

• Take the screw, washer and mounting plate from the kit. Install the front engine block heater socket. Slide it as far to the left as possible. Tighten
• Route the cable to the left, in through the rubber seal on the left-hand side of the radiator. Continue down to the right-hand side of the front left side member.

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

Illustration A applies to the S60, and V70 XC (01-)

• Insert the cable through the uppermost hole to the left in the front grille. Insert the cable inside the weatherstrip at the edge of the front grille
• Install the front engine block heater socket. Tighten the front engine block heater socket using the screw.

Illustration B applies to the V70 and S80 up to and including -2003 (CH -334999)

Illustration C applies to the V70 and S80 up to and including -2003 (CH -334999)

• Place the front grille on a table with the front facing upwards. See the illustration
• Place a weight on one end of the front grille so that it does not move
• Take the cable from the kit
• Insert a plastic weatherstrip tool down into the fourth gap in the left side of the grille. Carefully twist the weatherstrip tool so that the plates in the grille bend away from each other. Twist so that the cable connector can be inserted through the front grille
• Repeat the operation using the joint box for the black cable. Only bend the plates enough so that the junction box can be inserted between the plates. Do not damage the plates.

Illustration D applies to the V70 and S80 up to and including -2003 (CH -334999)

• Install the front engine block heater socket 50 mm (2”) from the top edge of the front grille. Tighten the front engine block heater socket using the screw.

Applies to the S60, V70 and S80 up to and including -2003 (CH -334999)

• Reinstall the front grille. Reinstall the clips that hold the top edge of the front panel.

Points 12 - 13 apply to the S80 from model year 2003- (CH 335000-)

• Insert the cable for the front engine block heater socket through the top hole in the row second in at the far left of the grille
• Take the screw and the mounting plate from the kit. Install the front engine block heater socket. Slide the front engine block heater socket as far to the left as possible. Then tighten.

• Insert the cable from the front engine block heater socket on the top and reverse of the collision member on the left-hand side of the radiator. Allow the cable to hang down
• Reinstall the bumper cover on the bodywork. Use screws and clips. Adjust the length of the cable at the front edge / left-hand side of the rubber seal
• Tighten the four M8 screws. Tighten to 24 Nm (18 lbf. ft.). Reinstall the covers.

Points 14 - 16 apply to the S60, V70 and S80

• Raise the car.

Applies to cars with side air baffles

• Remove the screw (1) in the left-hand air baffle (2). Remove the air baffle by pulling it backwards
• Repeat the operation for the right-hand air baffle.

Remove:

• the air baffle (2). First remove the screws (1). Press up the catches (5). Pull the air baffle downwards and backwards
• the splash guard (4) by slackening off the screws (3).

• Insert the cable from the front grille down to the left past the radiator. Continue under the car towards the pulsed secondary air injection system (PAIR) pump. (Also see the illustration in point 17).

Applies to all models

• Route the cable from the pulsed secondary air injection system (PAIR) pump, along the left-hand side, above the sub-frame. Continue up to the engine as illustrated
• Use tie straps to clamp the cable in the existing holes and to the oil cooler.

Осторожно: Do not clamp to the drive shaft. Ensure that the cable does not rub against any sharp edges.

Applies to cars with a T-stay. See the illustration

• Remove the stay.

Applies to all models

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

Осторожно: The heat conducting paste must be applied as illustrated to prevent damage caused by over heating.

Illustration A applies to cars with a T-stay. See the illustration

Illustration B applies to cars without a T stay

• Clean the area where the heater will be positioned. This ensures optimal heat conduction to the cylinder block. Also clean the internal thread
• Connect the cable supplied to the heater
• Install the heater on the cylinder block. See the illustration
• Install the spacer washer (1), (t=10 mm (25/64”)) between the mounting bracket (2) and the mounting hole (3) in the cylinder block. Install the outer spacer washer (4) (t=32 mm (1 1/4”)) between the mounting bracket (2) and the T-stay, if applicable
• Screw the heater into place. Use the screw from the kit. Tighten to 16 Nm (12 lbf. ft.).

Applies to cars with five cylinder engines and a stay for the turbocharger (TC) from model year 2005-

Illustration A

• Knock away the spacer (1) from the stay. Grind off the welds if the spacers are tightly installed.

Illustration B

• Clean where the heater is to be located for optimum heat conduction to the cylinder block. Also clean the internal thread.

Подсказка: To facilitate installation of the heater on the cylinder block, first secure the tensioner (2) by the heater. Use a small piece of butyl tape. Then also secure the spacer sleeve (1) on the reverse of the tensioner. Use a small piece of butyl tape.

Примечание: The outward curved section of the tensioner must point away from the heater.

• Install the spacer washer (1), (t=10 mm (25/64”)) between the tensioner (2) and the mounting in the cylinder block (3). Install the outer spacer washer (4) (t=32 mm (1 1/4”)) on the outside of the bracket
• Thread the long screw (5) through to hold everything in place.

Illustration C

• Thread the heater and tensioner in place. Screw the turbocharger (TC) stay into place using the three screws as follows:
• Tighten the screws. Tighten to 16 Nm (12 lbf. ft.)
• Take the heat shield and cable from the kit. Thread the heat shield on the cable. Connect the cable to the heater
• Install the locking sleeve on the heater connector.

Примечание: Applies from the following chassis numbers:

• S60 CH 425000-
• V70 CH 459000-
• XC70 CH 173000-
• S80 CH 390000-
• XC90 CH 134000-.

Install:

• the air baffle
• the splash guard
• the decal from the kit.