Electrical engine block heater 230V (D5244T, D5244T2, D5244T3)

• Remove the overrider 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 overrider moulding according to the marking (1) on the reverse of the moulding. Use a utility knife or similar. Leave a safety margin when cutting. Finely adjust the size if 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 overrider moulding
• Install the protective cover (1) for the front engine block heater socket in the overrider moulding
• Mark out the hole in the bumper cover (2). Use a 29 mm (1 1/8") diameter hole saw and the centre drill bit
• Remove the protective cover. Drill out the hole using a 29 mm (1 1/8") diameter hole saw
• Remove any swarf
• Reinstall the protective cover.

• 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 remove the screws (1). Press up the catches (5). Pull the air baffle downwards and backwards
• the engine cover (4) by slackening off the screws (3).

Installing the front engine block heater socket

• Route 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.

• Measure out for a hole for the front engine block heater 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 the centre of the hole so that it is symmetrically positioned on the top of the bumper
• Pre-drill the hole. Use a 3 mm (1/8”) diameter drill bit
• Drill out the hole. Use a 30 mm (1 3/16”) drill bit
• Remove any swarf.

• Open the drain holes on both sides of the connector. Use a screwdriver and press in by hand at the markings.

• Install the expander nut in the hole, with the locating pin in the guide hole
• Route the cable, including the ground lead, from the front socket from above and downwards. Let them hang down.

Installing the front engine block heater socket

• Connect the cable to the front engine block heater socket. Press downwards and turn the cable clockwise so that the expander nut engages
• Align the cable from the front socket so that the hinge is pointing towards the headlamp. Remove the cable.

• 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 headlamp connector. Use 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
• Pre-drill 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 the same height. This ensures a flat surface against which the plastic nut for the front engine block heater socket can be tightened.

• 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.

Installing the front engine block heater socket

Illustration A

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

Illustration B

• Install the plastic nut
• Tighten the plastic nut well. Connect the cable to the front engine block heater socket to use as a counterhold when tightening the plastic nut
• Route the wiring down along the left-hand side of the side member.

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

• Remove the three screws (1) holding the stay for the exhaust pipe at the cylinder block and exhaust pipe
• Remove the stay.

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

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

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

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

Applies to the S60 and V70 (00-)

• 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 locking sleeve (from the kit) over the cable splice on the cable
• Thread the radiated heat shield over the cable for the heater
• Install the heater on the cylinder block, as illustrated
• Install the screw with the tensioner and spacer sleeve from the kit. Tighten the heater. Tighten to 16 Nm (12 lbf.ft).

Applies to the S60 and V70 (00-)

• 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 heat shield completely covers the cable splice on the engine side.

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

Applies to the XC90

• Clean the area where the heater will be positioned. This ensures optimal heat conduction to the cylinder block. Also clean the internal thread
• Take the short joint cable and insert it up between the bevel gear and cylinder block, in front of the oil pipe to the turbocharger (TC)
• Take the engine block heater and secure it to the joint cable.

Applies to the XC90

• Install the engine block heater in the cylinder block by pressing the joint cable for the engine block heater down as far as possible between the bevel gear and cylinder block. The upper edge of the engine block heater must not be in contact with the engine coolant hose which runs along the cylinder block. Insert the engine block heater into the cylinder block.

Примечание: There is very little space to insert the joint cable between the bevel gear and cylinder block, great effort is therefore required to install the engine block heater. Ensure that the joint cable does not detach from the engine block heater when working as it cannot be connected when the engine block heater is in place. (Due to the lack of space, the locking sleeve cannot be secured above the joint cable before the engine block heater is installed.)

Applies to the XC90

• Press a locking sleeve (from the kit) over the cable junction.

Applies to the XC90

• Take the heat shield from the kit. Pull the 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 heat shield completely covers the cable splice on the engine side.
- Secure the heat shield around the cable to the engine block heater. Use a grey heat resistant tie strap in the lower edge of the heat shield.

Applies to the XC90

• Take a screw, spacer sleeve and tensioner from the kit. Secure the engine block heater to the cylinder block. Tighten the screw to the engine block heater. Tighten to 16 Nm (12 lbf.ft.).

• Remove the existing nut from the steering gear
• Install the mounting bracket for 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. Use 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-ring on the connector. Use low temperature grease, (P/N 1161417-9) (see point 15).

• Route the cable from the engine block heater over the oil cooler to the previously installed bracket
• 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.

Примечание: Clamp the cable securely at the oil cooler so that it is not chafed by the drive shaft.

• 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 XC90

• Reinstall the stay for the cylinder block and exhaust pipe. Tighten the screws. Tighten to 24 Nm (18 lbf.ft.).

Applies to the S60 and V70 (00-)

• Reinstall the centre air baffle
• Secure the engine block heater cable in the left mounting on the centre air baffle
• Reinstall the two air baffles at the sides.

Applies to all models

• Reinstall the engine splash guard. Tighten the screws for the engine splash guard. Tighten to 19 Nm (14 lbf.ft.).

Applies to the XC90

• Connect and reinstall the headlamp.