Adjustment
Extending the wiring for the water pump
Scheme 121
Cut off the cable harness for the water pump as close to the connector as possible.
Cut off part of the protective tube so that the 2 cables are exposed.
Strip the ends of the cables enough for the bonded shrink-fit terminals from the kit.
Scheme 122
Modify the length of the protective tube so that the stripped cable ends are only just protruding.
Thread the thin protective tube onto the cable harness extension.
Use the bonded shrink-fit terminals from the kit. Splice the cable harness extension to the stripped cables.
Note. The cable colors must match at each join.
Reinforce the exposed areas. Use insulation tape.
Scheme 123
Thread the thicker protective tube from the kit over the join.
Adjust the length so that it overlaps the thinner protective tubes by approximately 10 mm on each side.
Wind insulation tape around the join.
Installing the water pump and rubber cap
Scheme 124
Thread the new water pump into the existing rubber mounting using the marking made earlier.
Wind foam tape from the kit around the section of the water pump protruding from the rubber mounting.
Scheme 125
Install the water pump and rubber mounting on the screws for the engine block heater.
Route the water pump wiring as illustrated.
Connect the connector to the top of the water pump.
Thread the rubber cap from the kit over the cable harness and the upper section of the water pump.
Secure the rubber cap. Use the tie strap from the kit.
Installing components
Install
- the hoses on the pipe couplings for the water pump. Tighten the hose clamps
- the bracket for the control module. Tighten
- the control module.
Remove the hose clips from the hoses. Check that there is no leakage.
Install
- the air baffles on the left-hand and, if applicable on the right-hand side
- the air baffle in the center
- the bumper cover. See «CASING, BUMPER FRONT, REPLACING»(/volvo/s60/i-2000-2004/remont/exteriorinterior-trim/#panels-moulding-removal-installation__casing-bumper-front-replacing) .
Extending the wiring for the water pump
Cut off the cable harness for the water pump as close to the connector as possible.
Cut off part of the protective tube so that the 2 cables are exposed.
Strip the ends of the cables enough for the bonded shrink-fit terminals from the kit.
Modify the length of the protective tube so that the stripped cable ends are only just protruding.
Thread the thin protective tube onto the cable harness extension.
Use the bonded shrink-fit terminals from the kit. Splice the cable harness extension to the stripped cables.
Note. The cable colors must match at each join.
Reinforce the exposed areas. Use insulation tape.
Thread the thicker protective tube from the kit over the join.
Adjust the length so that it overlaps the thinner protective tubes by approximately 10 mm on each side.
Wind insulation tape around the join.
Installing the water pump and rubber cap
Thread the new water pump into the existing rubber mounting using the marking made earlier.
Wind foam tape from the kit around the section of the water pump protruding from the rubber mounting.
Install the water pump and rubber mounting on the screws for the engine block heater.
Route the water pump wiring as illustrated.
Connect the connector to the top of the water pump.
Thread the rubber cap from the kit over the cable harness and the upper section of the water pump.
Secure the rubber cap. Use the tie strap from the kit.
Installing components
Install
- the hoses on the pipe couplings for the water pump. Tighten the hose clamps
- the bracket for the control module. Tighten
- the control module.
Remove the hose clips from the hoses. Check that there is no leakage.
Install
- the air baffles on the left-hand and, if applicable on the right-hand side
- the air baffle in the center
- the bumper cover. See: «Casing, Bumper Front, Replacing»(/volvo/s60/i-2000-2004/remont/exteriorinterior-trim/#panels-moulding-removal-installation) .
Extending the wiring for the water pump
Cut off the cable harness for the water pump as close to the connector as possible.
Cut off part of the protective tube so that the 2 cables are exposed.
Strip the ends of the cables enough for the bonded shrink-fit terminals from the kit.
Modify the length of the protective tube so that the stripped cable ends are only just protruding.
Thread the thin protective tube onto the cable harness extension.
Use the bonded shrink-fit terminals from the kit. Splice the cable harness extension to the stripped cables.
Note. The cable colors must match at each join.
Reinforce the exposed areas. Use insulation tape.
Thread the thicker protective tube from the kit over the join.
Adjust the length so that it overlaps the thinner protective tubes by approximately 10 mm on each side.
Wind insulation tape around the join.
Installing the water pump and rubber cap
Thread the new water pump into the existing rubber mounting using the marking made earlier.
Wind foam tape from the kit around the section of the water pump protruding from the rubber mounting.
Install the water pump and rubber mounting on the screws for the engine block heater.
Route the water pump wiring as illustrated.
Connect the connector to the top of the water pump.
Thread the rubber cap from the kit over the cable harness and the upper section of the water pump.
Secure the rubber cap. Use the tie strap from the kit.
Installing components
Install
- the hoses on the pipe couplings for the water pump. Tighten the hose clamps
- the bracket for the control module. Tighten
- the control module.
Remove the hose clips from the hoses. Check that there is no leakage.
Install
- the air baffles on the left-hand and, if applicable on the right-hand side
- the air baffle in the center
- the bumper cover. See «Casing, Bumper Front, Replacing»(/volvo/s60/i-2000-2004/remont/exteriorinterior-trim/#panels-moulding-removal-installation__casing-bumper-front-replacing) .