Climate Units - Installation Instructions, Accessories (Xc): Overview Volvo V70 II

Scheme 914

1. Clean the bumper cover where the two pieces of tape will be secured
2. Apply two pieces of tape to mark the holes for the engine block heater switch (use thin tape). Apply one piece of tape at the rear edge, under the corner of the indicator lamp, vertically down. Position the underside of the second piece of tape along the upper radius of the bumper cover as illustrated.

Scheme 915

1. Mark up a rectangle on the inside of the corner where the two pieces of tape intersect. See the measurements in the illustration. The distance from the edges of the tape must be 5 mm (13/64")
2. Apply tape to the surface of the bumper which is to be cut. This is to protect the bumper skin
3. Carefully cut out the bumper cover. Follow the markings. Use a utility knife or similar
4. Even off the edges.

Scheme 916

1. Remove the pieces of tape
2. Take the protective cover (1) for the front engine block heater socket from the kit. Press the protective cover into the cut out. Ensure that the section of the cover where the hole is nearest the edge is pointing forwards
3. Mark out the hole in the bracket (2) inside the bumper cover. Use a 29 mm (1 1/8") diameter hole saw without the central drill bit
4. Remove the protective cover. Drill out the hole using a 29 mm (1 1/8") diameter hole saw
5. Remove any metal shavings.

Scheme 917

1. File out a small 4 x 4 mm (5/32" x 5/32") cut out in the lower edge of the hole in the protective cover. The hole is intended for the lug on the expander nut. This is used to secure the front engine block heater socket
2. Reinstall the protective cover.

Scheme 918

1. Install the expander nut (1) in the hole
2. Thread the cable supplied (2), including the ground lead, through the hole
3. Take the connection cable (3) from the kit. Assemble it using the cable at the expander nut. Screw clockwise so that the expander nut expands
4. Remove the connection cable. NOTE: Ensure that the drainage hole for the front engine block heater socket is open.

Scheme 919

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 920

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 921

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

Scheme 922

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 923

1. Remove the stay.

Scheme 924

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 illustrated
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 lb. ft.) .

Scheme 925

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 illustrated
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 lb. ft.) .

Scheme 926

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 927

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

Scheme 928

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 929

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 lb. 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 930

1. Disconnect the hose for preheating the intake air.

Scheme 931

1. Remove the screws (1) for the preheating plate over the manifolds.

Scheme 932

1. Disconnect the cable to the right-hand heated oxygen sensor (HO2S) and the clamp (1) from the bracket (2)
2. Remove the bracket.

Scheme 933

1. Remove the two heated oxygen sensors (HO2S) from the manifolds. 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.
2. Mark up the heated oxygen sensors (HO2S) so that they are reinstalled in the correct position and are not mixed up.

Scheme 934

1. Clamp the heated oxygen sensors (HO2S) with the twisted cables by the pipe for the air conditioning (A/C) system so that the cables resume their normal position when installing the heated oxygen sensors (HO2S). Use tie straps.

Scheme 935

1. Remove the preheating plate over the manifolds.

Scheme 936

1. Remove the nuts in the flange at the joint between the manifolds and the exhaust pipes.

Scheme 937

1. Remove the screws for the front side impact protection member.

Scheme 938

1. Remove the brake pipe from the clamps in the side impact protection member
2. Remove the clamp holding the cable to the left rear heated oxygen sensor (HO2S) from the side impact protection member
3. Remove the side impact protection member
4. Pull the exhaust pipes off the manifolds. Allow them to rest on the rear side impact protection member.

Scheme 939

1. Clean and spray rust solvent spray on the free ends of the studs for the left-hand manifold
2. Remove the nuts (1) for the left-hand manifold mounting on the engine
3. Pull the manifold off the exhaust pipe. Lift the manifold up from the engine. Place the manifold to one side.

Scheme 940

1. Remove the existing nut from the steering gear
2. Install the mounting bracket for the junction switch and cables
3. Install the lock nut from the kit. Tighten to 48 Nm (36 lb. ft.)
4. Secure the first tie strap on the power steering pipe. If there is no servo coolant pipe; drill out the first hole to a diameter of 6.5 mm (1/4") . Secure the tie strap as normal. 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 (TC) or exhaust pipe to prevent damage from radiant heat.

Scheme 941

1. Install the Y connector on the bracket. Use the screw and the nut from the kit
2. Lubricate the O-rings. Use low temperature grease, (P/ N 1161427)
3. Connect the wiring from the front engine block heater socket (1), the passenger compartment socket (3) and the engine block heater (2) to the Y-connector
4. Tighten the Y connector and the bracket on the steering gear. Tighten to 48 Nm (36 lb. ft) .

Scheme 942

1. Route the cable from the bumper to the cable from the engine block heater. See the illustration
2. Clamp the cable in the existing holes and to the oil cooler pipe. Use tie straps
3. Connect the cable from the bumper to the cable from the engine block heater. Alternatively connect the cable from the bumper to the Y connector. 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 (TC) or exhaust pipe to prevent damage from radiant heat.

Scheme 943

1. Install the locking sleeves over all the connectors and cable splices on the wiring. Ensure that these are correctly installed.

1. Reinstall the air baffles and the splash guard.
2. Tighten the splash guard screws. Tighten to 25 Nm (19 lb. ft)
3. Clamp the engine heater cable in the mounting on the left-hand side of the air baffle.