Volvo 30661683 User manual

Instruction No Version Part. No.
30661683 1.2 30661683
Electric engine block heater, 110V, 6 - cyl
IMG- 305983
Instruction No Version Part. No.
30661683 1.2 30661683
Electric engine block heater, 110V, 6 - cyl
IMG- 305983
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Electric engine block heater, 110V, 6 - cyl - 30661683 - V1.2
Page 1 / 18

Equipment
A0000162 A0000163 A0000161
IMG- 231673
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Electric engine block heater, 110V, 6 - cyl - 30661683 - V1.2
Page 2 / 18

IMG- 214041
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Electric engine block heater, 110V, 6 - cyl - 30661683 - V1.2
Page 3 / 18

INTRODUCTION
Read through all of the instructions before starting installation.
Notifications and warning texts are for your safety and to
minimise the risk of something breaking during installation.
Ensure that all tools stated in the instructions are available
before starting installation.
Certain steps in the instructions are only presented in the form
of images. Explanatory text is also given for more complicated
steps.
In the event of any problems with the instructions or the
accessory, contact your local Volvo dealer.
1
IMG- 231674
Clean the surface where the front engine block heater socket
will be secured.
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Electric engine block heater, 110V, 6 - cyl - 30661683 - V1.2
Page 4 / 18

2
IMG- 231675
Drill a hole for the guide to the front engine block heater socket's
mounting plate.
File down the edges of the holes.
3
IMG- 231677
Drill a hole for the tie strap for the front engine block heater
socket's cable.
File down the edges of the holes.
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Electric engine block heater, 110V, 6 - cyl - 30661683 - V1.2
Page 5 / 18

4
IMG- 231681
Cut away the three pins on the front engine block heater
socket's mounting plate.
5
IMG- 214067
Drill a Ø 5 mm (3/16 ") hole in the mounting plate.
File down the edges of the holes.
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Electric engine block heater, 110V, 6 - cyl - 30661683 - V1.2
Page 6 / 18

6A
IMG- 231684
6B
R2900280
6C
R2900283
Illustration A, B, C and D
Assemble the front engine block heater socket with the parts
from the kit as illustrated.
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Electric engine block heater, 110V, 6 - cyl - 30661683 - V1.2
Page 7 / 18

6D
IMG- 231683
7
IMG- 231685
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.
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Electric engine block heater, 110V, 6 - cyl - 30661683 - V1.2
Page 8 / 18

8
IMG- 231686
Drill a hole with a Ø 5 mm (3/16 ") drill bit for the screw for
securing the front engine block heater socket's mounting plate.
9
IMG- 231688
Secure the front engine block heater socket with a screw and
nut in the drilled hole and tighten.
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Electric engine block heater, 110V, 6 - cyl - 30661683 - V1.2
Page 9 / 18

10
IMG- 231689
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.
11
IMG- 365041
Remove the expansion tank cover.
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Electric engine block heater, 110V, 6 - cyl - 30661683 - V1.2
Page 10 / 18

12
IMG- 231691
Remove the engine splash guard.
13
IMG- 231694
Detach the nipple and drain the coolant.
Retighten the nipple after the coolant has been drained.
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Electric engine block heater, 110V, 6 - cyl - 30661683 - V1.2
Page 11 / 18

14
IMG- 231697
Rotate the catch on the coolant pipe that runs to thermostat
housing anticlockwise, pull the hose out and drain the remaining
coolant.
15
IMG- 231698
Detach the hose clamp on the hose to the thermostat housing
inside the intake manifold and remove the hose.
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Electric engine block heater, 110V, 6 - cyl - 30661683 - V1.2
Page 12 / 18

16
IMG- 231699
Cut the removed hose as illustrated. First cut to a dimension of
52 mm (1 1/16 ").
Discard the small cut -off hose bend.
17
IMG- 231700
Reinstall the longer of the hose sections onto the thermostat
housing's connection and tighten the hose clamp. Make sure that
the cut-out in the upper hose-end fits into the corresponding pin
in the pipe connection in the thermostat housing.
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Electric engine block heater, 110V, 6 - cyl - 30661683 - V1.2
Page 13 / 18

18
IMG- 231703
Remove the short hose-end and press it on the pipe that runs to
the thermostat housing. Make sure that the cut-out in the hose
connection is turned down and fits into the corresponding pin in
the pipe connection.
Rotate the catch on the pipe clockwise against the stop.
Take a hose clamp from the kit and install it on the hose -end.
19
IMG- 231478
Take the engine block heater, bracket, rubber coated clamp and
screw from the kit and assemble them as illustrated.
Do not tighten the screw yet.
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Electric engine block heater, 110V, 6 - cyl - 30661683 - V1.2
Page 14 / 18

20
IMG- 231479
Take the hose clamp from the kit and fit it onto the engine block
heater's upper connection.
21
IMG- 231480
Position the engine block heater with bracket in the front edge of
the oil sump and connect both hose-ends to the engine block
heater's connections.
Take a screw from the kit and tighten the bracket with engine
block heater into the existing hole in the oil sump.
Note!
The screw is self-tapping so inserting it may be slow. Make
sure that the screw is centred straight into the hole, so that the
screw head is flat against the bracket.
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Electric engine block heater, 110V, 6 - cyl - 30661683 - V1.2
Page 15 / 18

22
IMG- 231704
Now adjust the engine block heater in the rubber coated clamp
so that the hoses are properly fitted on the engine block heater's
connections.
Tighten the screw to the rubber coated clamp.
Tighten the hose clamps to the engine block heater.
23
IMG- 231705
Take five double tie straps from the kit and secure them on the
pipe and hose to the thermostat housing as well as the lower
hose to the radiator.
Check that the cable does not chafe against sharp edges or
moving parts in the engine compartment.
Caution!
Do not clamp the cable directly to brake pipes, fuel lines, AC
pipes or pipes to the power steering.
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Electric engine block heater, 110V, 6 - cyl - 30661683 - V1.2
Page 16 / 18

24
IMG- 231706
Take a tie strap equipped with clip and press it into the hole on
the top of the left-hand bracket for the skid plate.
25
D3601932
Grease in the O -ring on the connector on the cable to the front
engine block heater socket, use low temperature grease P/N
1161427.
Note!
Do not get any grease on the surfaces of the connector.
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Electric engine block heater, 110V, 6 - cyl - 30661683 - V1.2
Page 17 / 18

26
IMG- 231707
Connect the cable in the engine block heater and press it in
firmly.
Press a locking sleeve from the kit over the cable splice.
27
IMG- 231708
Clamp the joint cable from the engine block heater into the
recently installed tie straps. Clamp up all excess cable around
the tie strap on the top of the skid plate bracket.
If necessary, use another tie strap for clamping the cable behind
the skid plate.
28
Fill with coolant, run the engine to operating temperature, bleed
the cooling system and check that there are no leaks.
Top up the cooling system as required.
Reinstall the engine splash guard and torque tighten the screws
to 25 Nm (18.5 lbf.ft.).
Installation instructions, accessories
Volvo Car Corporation Gothenburg, Sweden
© Volvo Car Corporation Electric engine block heater, 110V, 6 - cyl - 30661683 - V1.2
Page 18 / 18