XC90 L5-2.5L Turbo VIN 59 B5254T2 (2004)
Disconnect the fan motor connector.
Disconnect the flame sensor from the mounting.
Replacing the entire cable harness:
Remove the entire cable harness forallsensors.
Hint: Replace the cable harness by removing it piece by piece. Replace in the same order with a new cable harness so that it is correctly positioned.
Cutting and splicing the cable harness:
To replace individual sensors, cut and splice the cable harness. See Splicing the cables See: Diagrams/Diagnostic Aids/Wiring/Splicing the Cables.
Installing the overheat protection, thermostat flame sensor and coolant temperature sensor
Install:
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the new cable harness
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all the sensors and connectors
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the fan shroud
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the intake hose
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the control module. See Control module engine coolant heater, replacing See: Auxiliary Cabin Heater Control Module/Service and Repair
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the overheat protection thermostat using a nut (1xM5). Tighten. See Tightening torque See: Body and Frame/Specifications
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the engine coolant temperature sensor
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the cover with a nut. Tighten. See Tightening torque See: Body and Frame/Specifications
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the heater. See Engine coolant heater, replacing See: Service and Repair/Engine Coolant Heater, Replacing.
Final check
Test run the heater. Check the function of the heater. See Engine coolant heater, test running See: Testing and Inspection/Component Tests and General
Diagnostics/Engine Coolant Heater, Test Running.
Check that no diagnostic trouble codes (DTC) have been stored during the repair work.
Install the bumper cover. See Casing bumper front, replacing See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and
Repair.