Electric Engine Block Heater, 110V

Electrical engine block heater, 5-cyl. 110V
























Electrical engine block heater, 5-cyl. 110V

Preparations




- Turn the seven clips 90°. Release the engine splash guard from the clips. Place the engine splash guard to one side.




- Remove the left front wheel
- Remove the five screws holding the bumper cover in the wing liner on the left and right-hand sides.




- Remove the nut holding the left-hand wing liner to the front member
- Bend the front edge of the left-hand wing liner up over the brake calliper.




- Push in the centre of the five clips (1). Remove the clips
- Remove the two screws (2).

Illustration A




- Remove the cover for the headlamp high-pressure cleaning nozzles on the right and left-hand sides. Carefully grip the cover. Pull the cover out until the catch becomes accessible.

Illustration B




- Press the catch up. Remove the cover. Do not damage the painted surfaces or the high-pressure cleaning nozzles.




- Detach the ends of the bumper cover on the left and right-hand sides. Grasp the end of the bumper cover inside the wing liner. Carefully pull the end of the bumper cover so that the two catches on the inside release
- Remove the bumper cover and air baffle. Pull the bumper cover and air baffle forwards until the remaining catches under the lamps release
- Disconnect the connectors for the fog lamps if applicable.

Installing the front engine block heater socket

- Assemble the front engine block heater socket using the parts from the kit. See illustrations A, B, C and D.

Illustration A





Illustration B





Illustration C





Illustration D









- Cut away the small lug on the rear mounting plate from the kit.

Illustration A




- Insert the cable through the uppermost hole to the left in the lower front grille.

Illustration B




- Install the front engine block heater socket connector in the hole underneath. Centre it in the middle of the hole. Tighten the connector using the screw and the mounting plate from the kit.

Cable routing




- Install three clips from the kit on the panel edge on the underside of the left front member.

Illustration A




- Reinstall the bumper cover. Use the five clips and the two screws at the top. Remove the air baffle from the lower section of the bumper cover. This makes it possible to route the cable between the left-hand end of the front grille and the seal in front of the radiator
- Route the cable for the front engine block heater socket through at the seal by the left-hand end of the lower front grille. Route the cable over the left-hand bracket (1) for the radiator and up to the underneath of the side member. Route the cable along the underneath of the front member and over the drive shaft. Raise the cable a little in the engine compartment.

Illustration B




- Press the cable into the previously installed clips
- Reinstall the air baffle in the bumper cover. Secure the air baffle to its rear mounting in the bracket, underneath the radiator
- Reconnect the connectors for the fog lamps if applicable
- Press the ends of the bumper cover into place on the body.




- Locate the cable as illustrated. Secure the cable to the strut using the tie strap from the kit.




- Install the three clips from the kit at the front of the panel over the windscreen wiper motor
- Slide the cable up to the top of the engine compartment to the position illustrated.

Illustration A




- Press the cable for the front engine block heater socket into the installed clips. Slide down the cable at point (1). Route the cable through the engine compartment (behind the A/C pipes) down to the strut at the mounting for the right-hand control arm.

Illustration B




- Secure the cable from the top of the engine compartment downwards using a tie strap.

Note! The cable must not be secured to the fuel lines, air conditioning (A/C) pipes or brake pipes.




- Secure the cable from the front engine block heater socket at the top by the strut. Use a tie strap from the kit.




- Grease the O-ring on the front engine block heater socket connector using low temperature grease (P/N 1161417-9).

Note! Do not get any grease on the contact surfaces of the connector.

Installing the engine block heater




- Remove the cover on the radiator expansion tank
- Unscrew the drain nipple in the radiator pipe above the oil cooler, in front of the right-hand drive shaft. Drain the coolant.




- Remove the left-hand radiator hose from the radiator pipe and the oil cooler. Place the radiator hose to one side as it will not be reused. There is a new hose in the kit.




- Install the heater in the bracket in the position illustrated. Use a rubber-covered clamp, screw and nut from the kit
- Saw off the protruding part of the screw level with the nut.

Illustration A





Illustration B




- Secure the two hoses (from the kit) on the engine block heater. Ensure that the end of the short hose is facing forwards towards the bracket (Illustration A). Ensure that the marking on the long hose is facing the underside (Illustration B)
- Tighten the hoses to the engine block heater. Use two hose clamps from the kit.




- Take two new hose clamps from the kit. Thread on the two hose ends.




- Install the bracket together with the heater behind the oil cooler. Tighten the bracket using the three screws and three spacer sleeves from the kit.

Note! The screws are self-tapping, so it may be difficult to screw them in. Ensure that the screws are centered straight in the holes. The screw heads must be positioned flat against the bracket.




- Take the insulation from the kit. Thread it onto the cable to the heater.




- Take the two coolant hoses (1) from the kit. Connect the coolant hoses to the oil cooler and the radiator pipe
- Securely tighten the two hose clamps
- Connect the cable (2) (previously routed) to the engine block heater. Press it securely into place in the engine block heater connector
- Press a locking sleeve from the kit over the joint
- Pull the insulation so that it covers the cable splice at the heater.

Illustration A




- Take two double tie straps from the kit. Press the cable into place by the heater hose and the power steering pipe
- Take the grey tie strap (1) from the kit. Secure the insulation at the cable.

Illustration B applies to turbocharged cars




- Illustration B displays the routing of the cable between the engine block heater and the splice, in the case of turbocharged cars and two-wheel drive cars. The cable is secured using two double clamps. The insulation is secured using a grey tie strap as in Illustration A.

- Reinstall the left-hand wing liner. Secure the wing liner to the left-hand side member
- Tighten the two wing liners to the bumper cover on the right and left-hand sides
- Fill with coolant. Run the engine to operating temperature. Bleed the cooling system. Check for leakage.




- Cut out the engine splash guard according to the markings on the outside
- Smooth off the edges using a file. Round off the corners on the outside of the engine splash guard
- Reinstall the engine splash guard
- Reinstall the front wheel. Tighten the wheel nuts. Tighten to 90 Nm (66 lbf. ft.).