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5L Turbo VIN 59 B5254T2 Engine Block Heater Service and Repair,

1 Engine Block Heater, Service and Repair, Removal and Replacement: Ele... 1 of 21 9/30/2011 3:16 PM 2005 Volvo S60 L5-2.5L Turbo VIN 59 B5254T2 Engine Block Heater Service and Repair, Removal and Replacement: Electric Engine Block Heater, 110V Electric engine block heater, 5-cyl. 110V

2 of 21 9/30/2011 3:16 PM INTRODUCTION - NOTE! Read through the whole installation instruction before starting the work. - The front page gives the date of this edition and the edition it replaces - The second page shows the tools needed for the installation and the contents of the installation kit - The illustrations display the procedure in order of operation. The order of operation is repeated in the text section

in the centers of the six clips until a click is heard. Remove the clips. - Pull the top edge of the front forward.

3 of 21 9/30/2011 3:16 PM - Cut out the text page in order to follow the illustrations and text at the same time. Electric engine block heater, 5-cyl. 110V Preparations, applies to the S60/V70/S80 Image A applies to the S60 and V70 Image B applies to the S80 up to and including model year (CH ) - Press in the centers of the six clips until a click is heard. Remove the clips. - Pull the top edge of the front forward. - Insert a hand inside and press the four catches that are evenly distributed along the upper edge up/down. Use a plastic weatherstrip tool. - Pull the front grille at the top until the catches release. Image A applies to the S60 and V70

Image B applies to the S80 up to and including model year -2003 (CH -334999) - Depress the three catches at the lower

4 of 21 9/30/2011 3:16 PM - Take a weatherstrip tool and insert it between the front grille and bumper cover, and carefully prize the front grille away along the whole of the bottom edge. It is secured with three clips. Image B applies to the S80 up to and including model year (CH ) - Depress the three catches at the lower edge of the front grille using a small screwdriver or similar, remove the front grille. Steps 3-6 apply to the S80 from model year (CH )

of 21 9/30/2011 3:16 PM - Remove the nut and wiper arm for headlamp washing. - Detach the hose for washing at the existing joint. - Carefully pry off the parking lamp at the front edge.

5 of 21 9/30/2011 3:16 PM - Remove the nut and wiper arm for headlamp washing. - Detach the hose for washing at the existing joint. - Carefully pry off the parking lamp at the front edge. Use a plastic weatherstrip tool. - Detach the connector and place the position lamp to one side. - Repeat the operation on the other side. - Remove the molding under the headlamp. Use a weatherstrip tool. Note! Do not damage the paintwork. - Repeat the operation on the other side.

of 21 9/30/2011 3:16 PM - Press in the center of the clips at the top edge of the bumper cover and remove them. - Remove the covers in front of the bumper cover's lower screws.

- Remove the screw in the rear/top edge of the bumper cover. - Repeat the operation on the other side. - Carefully pull away the end face of the bumper cover from the body.

6 of 21 9/30/2011 3:16 PM - Press in the center of the clips at the top edge of the bumper cover and remove them. - Remove the covers in front of the bumper cover's lower screws. - Remove the screws in the bumper cover. - Press the center of the clip at the lower edge/side of the bumper and remove it. - Remove the screw in the rear/top edge of the bumper cover. - Repeat the operation on the other side. - Carefully pull away the end face of the bumper cover from the body. It is fitted with four catches on the inside in the top edge and two in the bottom edge. - Repeat the operation on the other side. - Pull the bumper cover forwards, detach the connectors for the fog lamps if fitted. Assembling the front intake

of 21 9/30/2011 3:16 PM Applies to the V70, and S80 up to and including model year -2003 (CH -334999) - Cut off the shaded sections on the mounting plates as illustrated in figures A and C.

7 of 21 9/30/2011 3:16 PM Applies to the V70, and S80 up to and including model year (CH ) - Cut off the shaded sections on the mounting plates as illustrated in figures A and C. Applies to the S80 from model year (CH ) - Cut of the shaded section on the mounting plate as illustrated in figure B. Applies to the XC90 up to and including model year (CH ), and S60/V70/S80 - Assemble the front intake according to figure D. Installing the front intake, applies to the XC90 Steps 8-10 applies to the XC90 up to and including model year (CH ) - Guide the front socket's cable in through the center hole, next furthest to the left in the grille.

of 21 9/30/2011 3:16 PM - Take a screw, washer and attaching plate from the kit and install the front socket. Push it as far to the left as possible and tighten it.

8 of 21 9/30/2011 3:16 PM - Take a screw, washer and attaching plate from the kit and install the front socket. Push it as far to the left as possible and tighten it. - Pull the cable to the left, in through the rubber seal on the left-hand side of the radiator, continue down by the left front side, on the right-hand side. - Remove the engine splash guard (1) by first removing the screws (2). Steps apply to the XC90 from and including model year (CH )

9 of 21 9/30/2011 3:16 PM - Clean the surface where the front engine block heater socket will be secured. - Drill a hole for the guide to the front engine block heater socket's mounting plate. - File down the edges of the holes. - Drill a hole for the tie strap for the front engine block heater socket's cable.

10 Engine Block Heater, Service and Repair, Removal and Replacement: Ele of 21 9/30/2011 3:16 PM - File down the edges of the holes. - Cut-off all shaded sections on the mounting plate so that only the cylinder shaped section remains. - Drill a -5 mm (3/16 ") diameter hole in the mounting plate. - File down the edges of the holes.

1 of 21 9/30/2011 3:16 PM - Assemble the front intake as illustrated. The mounting plate (A) must not be used. - Install the front engine block heater socket with the guide pin in the large hole.

11 1 of 21 9/30/2011 3:16 PM - Assemble the front intake as illustrated. The mounting plate (A) must not be used. - Install the front engine block heater socket with the guide pin in the large hole. - Route the cable in so that it runs down on the inside of the left-hand bracket for the skid plate. - Align the front engine block heater socket so that the long sides of the mounting plate are parallel with the edges of the surface into which the mounting plate shall be screwed. - Mark out for drilling the hole for the screw for the mounting plate. - Drill a hole with a - 5 mm (3/16 ") diameter drill bit for the screw for securing the front engine block heater socket's mounting plate.

12 Engine Block Heater, Service and Repair, Removal and Replacement: Ele of 21 9/30/2011 3:16 PM - Secure the front engine block heater socket with a screw and nut in the drilled hole and tighten. - Secure the tie strap in the hole around the front engine block heater socket's cable. - Fold in the connector so that the cable adopts the correct length in the tie strap before it is tightened. - Tighten the tie strap.

inside of the left-hand side of the subframe.

13 3 of 21 9/30/2011 3:16 PM - Clamp the cable in at the pipe for the air conditioning using a double tie strap. - Remove the engine splash guard. - Pull the cable from the front intake over the skid plate, above the inside of the front left-hand side corner of the subframe, and down to the inside of the left-hand side of the subframe. - Take the tie strap equipped with clip and press it into the hole on the top of the left-hand bracket for the skid plate. - Tighten the cable with the tie-strap. Installing the front intake, applies to the S60/V70/S80 Image A applies to the S60 and XC70

front grille. The cable must be inserted inside the weatherstrip at the edge of the front grille.

14 Engine Block Heater, Service and Repair, Removal and Replacement: Ele of 21 9/30/2011 3:16 PM - Insert the cable through the next upper hole along to the left in the front grille. The cable must be inserted inside the weatherstrip at the edge of the front grille. - Reinstall the front intake and tighten it with the screw. Image B and C apply to the V70, and S80 up to and including model year (CH )

5 of 21 9/30/2011 3:16 PM - Place the front grille with the front facing upwards on a table, as illustrated. - Place a weight on one end of the front grille so that it remains still.

15 5 of 21 9/30/2011 3:16 PM - Place the front grille with the front facing upwards on a table, as illustrated. - Place a weight on one end of the front grille so that it remains still. - Take the electrical cable from the kit. - Take a plastic weatherstrip tool or similar and insert it down into the fourth compartment in the left-hand side of the front grille, and turn the tool carefully so that the plates in the front grilled are separated from each other. Turn so that the cable's connector can be inserted through the front grille. - Carry out the same procedure with the cable's black joint section, but do not bend the plates more than the join section can pass between them as this can damage the plates. Image D applies to the V70, and S80 up to and including model year (CH ) - Install the front intake 50 mm (2") from the upper edge of the front grille, and tighten using the screw. Applies to the S60, V70, and S80 up to and including model year (CH ) - Reinstall the front grille and clips at the upper edge on the front. Steps apply to the S80 from model year (CH ) - Guide the front intake's cable in through the uppermost hole in row, next furthest to the left in the grille. - Take screws and mounting plate from the kit. Install the front intake and slide it to the left as far as possible. Tighten.

6 of 21 9/30/2011 3:16 PM - Insert the cable from the front intake on the upper side and rear side of the collision member on the left-hand side of the radiator and

- Tighten the four M8 screws to 24 Nm (18 lbf.ft.) and reinstall the covers. Steps 28-30 apply to the S60, V70 and S80 - Raise the car.

16 6 of 21 9/30/2011 3:16 PM - Insert the cable from the front intake on the upper side and rear side of the collision member on the left-hand side of the radiator and allow them to hang down. - Reinstall the bumper cover to the body using screws and clips. Align the length of the cable by the front edge/left side of the rubber seal. - Tighten the four M8 screws to 24 Nm (18 lbf.ft.) and reinstall the covers. Steps apply to the S60, V70 and S80 - Raise the car. Applies to cars with side air baffles - Remove the screw (1) from the left-hand air baffle (2), and remove the air baffle by pulling it backwards. - Carry out the same procedure on the right-hand air baffle.

17 7 of 21 9/30/2011 3:16 PM Remove: - the air baffle (2) by undoing the screws (1), pressing up the catches (5) and moving the air baffle down and back. - the splash guard (4) by undoing the screws (3). - Move the cable from the front grille down to the left, passing the radiator and under the car to the air pump. (Also see image in point 30). Installing, engine block heater Applies to models - Pull the cable above the subframe and on the inside of its left front mounting, along the left-hand side and up towards the engine. - Clamp the cable using tie straps in the existing holes and with double clamps at pipes on the oil cooler. Caution! Do not clamp the drive axle, and ensure that the cable does not chafe against sharp edges.

18 8 of 21 9/30/2011 3:16 PM Applies to cars with T stay, as illustrated - Remove the stay. Applies to models - Apply heat conducting paste, (P/N ), on the surfaces (1) of the heater body that are in contact with the cylinder block. Caution! The heat conducting paste must be applied as illustrated. This is to prevent damage from overheating. Image A applies to cars with T stay, as illustrated

9 of 21 9/30/2011 3:16 PM Image B applies to cars without T stay - Clean the area where the heater is to be installed. This ensures optimal heat conduction to the cylinder block.

- Install spacer washer (1) (t=10 mm (25/64")) between the mounting bracket (2) and mounting hole (3) in the engine block.

19 9 of 21 9/30/2011 3:16 PM Image B applies to cars without T stay - Clean the area where the heater is to be installed. This ensures optimal heat conduction to the cylinder block. Also clean the internal threads. - Connect the cable supplied to the heater. - Install the heater on the engine block, as illustrated. - Install spacer washer (1) (t=10 mm (25/64")) between the mounting bracket (2) and mounting hole (3) in the engine block. The outer spacer washer(4) (t=32 mm (1 1/4")) is inserted between the mounting bracket (2) and the T stay, if applicable. - Tighten the heater using the screws from the kit. Tighten to 16 Nm (12 lbf.ft.). Applies to cars with stay for the turbocharger from model year Note! - S60 CH V70 CH XC70 CH S80 CH XC90 CH Illustration A

20 0 of 21 9/30/2011 3:16 PM - Knock off the spacer (1) from the stay. Grind off the welds if the spacer is secured too tightly. Illustration B - Carefully clean the surface where the heater is to be located to provide good heat conduction to the engine block. Also clean the internal threads. Hint: To facilitate the installation of the heater on the engine block, first secure the tensioner (2) by the heater using a small piece of butyl tape and then also secure the spacer sleeve (1) on the rear side of the tensioner using a small piece of butyl tape. Note! The bent section of the tensioner must point away from the heater. - Install space washer (1)(t=10 mm (25/64")) between tensioner (2) and the mounting in the engine block (3). Install the outer spacer washer (4) (t=32 mm (1 1/4")) on the outside of the bracket. - Thread through the long screw (5) so that everything is held together. Illustration C

21 1 of 21 9/30/2011 3:16 PM - Thread the heater and the tensioner. Install the turbocharger stay and screw using the three screws as follows: - Screw the turbocharger stay into place through the tensioner in the mounting in the engine block, with the long screw (1). - Screw the turbocharger stay in the turbocharger with the short screw (2) and into the other mounting in the engine block with the screw (3). - Tighten the screws to 16 Nm (12 lbf.ft.). - Take the radiation protection and cable from the kit. Thread the radiation protection onto the cable and connect the cable to the heater - Install the locking sleeve on the heater's connector. Install: - air baffle - the splash guard. Tighten the screws to 25 Nm (18.5 lbf.ft.). - the decal from the kit ALLDATA, LLC. All Rights Reserved. (Version )

Installation instructions, accessories - Electric engine block heater

Installation instructions, accessories - Electric engine block heater S60 / V70 (00-08) / S80 (-06) / V70 XC (01-) / XC70 (-07) / XC90 Section Group Weight Year Month (Kg/Pounds) 8 876 2/4.4 2006 09 S60 2001 D5244T, S60 2002 D5244T, S60 2002 D5244T2, S60 2003 D5244T, S60