Engine Block Heater - Installation Instructions, Accessories: Overview Volvo S80 I

Scheme 572

1. Secure the adhesive template. Use the template to mark up the bumper for holes
2. Drill a hole. Use a 4 mm (5/32") diameter drill bit
3. Drill a hole at right-angles to the surface. Use a 29 mm (1 1/8") diameter hole saw
4. Adjust the guide hole using a round file
5. Also adjust the lead-in hole if necessary.

Scheme 573

1. Open the drain holes on both sides. Use a screwdriver. Press in by hand at the markings.

Scheme 574

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

Scheme 575

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

Scheme 576

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

Scheme 577

1. Raise the car
2. Remove the screw (1) from the left air baffle (2) for the front brake
3. Pull the left air baffle backwards. Remove the left air baffle
4. Remove the right air baffle in the same way.

Scheme 578

1. Remove the screws (1). Remove the air baffle (2)
2. Remove the screws (3). Remove the splash guard (4).

Scheme 579

Ground terminal for the cable under the member

1. Drill a hole. Use a 4 mm (5/32") diameter drill bit
2. Rust-proof and secure the ground lead. Use the 4.8 mm (3/16") diameter flanged screw and toothed washer included. NOTE: Connect the ground lead to the side member, not to the sub-frame.
3. Secure any excess ground lead. Use new tie straps.

Scheme 580

1. Remove the stay.

Scheme 581

1. Clean the area where the heater will be positioned. This ensures optimal heat conduction to the cylinder block. Also clean the internal thread
2. Thread the heat shield over the cable for the heater
3. Take the locking sleeve and the cable for the heater from the kit. Connect the cable to the heater. Install the locking sleeve over the joint on the cable
4. Install the heater on the cylinder block, as shown
5. Install the spacer washer (1), t=10 mm / 25/64", between the tensioner (2) and the mounting (3) in the cylinder block
6. Install the outer spacer washer (4), t=32 mm / 1 1/4", between the stay and the tensioner (2)
7. Screw the heater into place. Use the screw from the kit. Tighten to 16 Nm (12 lbf. ft.) .

Scheme 582

1. Open the cover for the radiator expansion tank
2. Position a container under the engine. Open the coolant drain cock
3. Drain the coolant. Close the drain cock.

Scheme 583

1. Pull out the core plug located in the middle of the cylinder block. Use an extractor.

Scheme 584

1. Thread the O-ring on to the heater
2. Lubricate the O-ring. Use low temperature grease, (P/N 1161427)
3. Screw the immersion heater into the cylinder block. Tighten to 3.5 Nm (2.6 lbf. ft.)
4. Take the locking sleeve and the cable for the heater from the kit. Connect the cable to the heater. Install the locking sleeve over the joint on the cable
5. Secure the cable at the pipe on the right-hand side at the rear edge of the sub-frame. Use a tie strap from the kit. NOTE: The cables must not be secured to the drive shaft, to the fuel lines, air conditioning (A/C) pipes or brake pipes. Check that the secured cable does not rub against any sharp edges. Check that the secured cable is not too close to the turbocharger unit or exhaust pipe to prevent damage from radiant heat.

Scheme 585

1. Clean the area where the heater will be positioned. This ensures optimal heat conduction to the cylinder block. Also clean the internal thread
2. Thread the heat shield over the cable for the heater
3. Take the locking sleeve and the cable for the heater from the kit. Connect the cable to the heater. Install the locking sleeve over the joint on the cable
4. Install the heater on the cylinder block, as shown
5. Install the spacer washer (1), t=10 mm / 25/64", between the tensioner (2) and the mounting (3) in the cylinder block
6. Install the outer spacer washer (4), t=32 mm / 1 1/4", outside the tensioner (2)
7. Screw the heater into place. Use the screw from the kit. Tighten to 16 Nm (12 lbf. ft.) .

Scheme 586

1. 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. NOTE: It is important that the heat shield completely covers the cable splice on the engine side.
2. Secure the heat shield around the cable to the engine block heater. Use a grey, heat resistant tie strap and clamp the bottom edge of the heat shield.

Scheme 587

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

Scheme 588

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

HINT: 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.

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

1. 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
2. Thread the long screw (5) through to hold everything in place.

Scheme 589

1. Thread the heater and tensioner in place. Screw the turbocharger (TC) stay into place using the three screws as follows: Screw the turbocharger (TC) stay into place through the tensioner in the cylinder block. Use the long screw (1) Screw the turbocharger (TC) stay into the turbocharger (TC). Use the short screw (2). Screw the turbocharger (TC) stay into the other mounting in the cylinder block. Use the screw (3).
2. Tighten the screws. Tighten to 16 Nm (12 lbf. ft.)
3. Take the heat shield and cable from the kit. Thread the heat shield on the cable. Connect the cable to the heater
4. Install the locking sleeve on the heater connector.

Scheme 590

1. Detach the engine stabilizer brace (1) by slackening off the screws (2) at each end, and the nut and screw (3) in the engine mounting
2. Remove the clamp for the servo hose on the right-hand side
3. Remove the engine stabilizer brace.

Scheme 591

1. Detach the charge air pipe (1) by slackening off the screw (2) and the hose clamps (3) at the rear edge
2. Remove the pipe by pulling it forwards.

Scheme 592

1. Disconnect the pipe (1) for the right-hand turbocharger (TC)
2. Remove the screw and clamp (2) at the turbocharger (TC).

Scheme 593

1. Disconnect the cables for the heated oxygen sensors (HO2S) from the clamp on the pipe to the turbo unit
2. Remove the two heated oxygen sensors (HO2S) by the turbo unit. NOTE: Twist the cables together when unscrewing the heated oxygen sensors (HO2S). Ensure that the cables are twisted along as great a length as possible to minimize the risk of damage. Keep them twisted.
3. Mark up the heated oxygen sensors (HO2S) so that they are reinstalled in the correct position and are not mixed up.

Scheme 594

1. Clamp the heated oxygen sensors (HO2S) with the twisted cables by the intake manifolds so that the cables resume their normal position when installing the heated oxygen sensors (HO2S). Use tie straps.

Scheme 595

1. Slacken off the screws for the heat shields. Remove the screws
2. Remove the heat shields.

Scheme 596

1. Clean the area where the heater will be positioned. This ensures optimal heat conduction to the cylinder block. Also clean the internal thread
2. Install the heater on the cylinder block from the top. HINT: First secure the tensioner (2) to the engine block heater. Use a small piece of butyl tape. Then secure the inner spacer washer (1), t =10 mm / 25/64", to the reverse of the tensioner. Use butyl tape.
3. Insert the engine block heater into the cylinder block. Take the outer spacer washer (4), t=32 mm / 1 1/4", and the screw. Insert the screw through the outer spacer washer, into the hole in the tensioner and through the inner spacer washer
4. Carefully move the engine block heater into position using the screw in the tensioner until the threaded cast protrusion (3) in the cylinder block is found
5. Finger tighten the screw
6. Take the extension cable and the heat shield from the kit. Thread the heat shield onto the extension cable
7. Lubricate the O-ring on the extension cable. Use low temperature grease, (P/N 1161417-9).

1. Take a locking sleeve from the kit. Connect the extension lead to the engine block heater. Press the locking sleeve into place over the joint.
2. 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. NOTE: Ensure that the heat shield covers the entire joint towards the engine.
3. Secure the heat shield around the cable to the engine block heater. Use a grey, heat resistant tie strap and clamp the bottom edge of the heat shield.
4. Tighten the engine block heater. Tighten to 16 Nm (12 lbf. ft.) .
5. Reinstall the heat shields.

See also:
• Cars equipped with SRS/SIPS (Airbag)
• S60/V70 (00-)/S80