Electric Engine Block Heater
Electric engine heater
230V
Electric engine heater
- Remove the bumper guard. Loosen the guard at one end using a thin plastic blade and pull it off.
- Cut a hole (1) in the bumper guard as marked at the rear of the strip. Use a carpet knife or similar tool and allow a certain margin.
Note! When cutting along the upper horizontal line, lean the knife against the upper edge of the strip as a guide to ensure that the cut is precisely in the middle of the rounded section.
- Smooth the edges of the hole with a file.
- Fit the protective cover (1) for the front intake in the bumper guard
- Place the guard in position but do not secure at this point
- Mark out the hole in the bumper cover (2) with the aid of a 29 mm (1 1/8") hole saw and centre bit
- Remove the bumper guard and protective cover and cut the hole with the same hole saw.-29 mm (11/8")
- Remove the swarf
- Refit the bumper guard, with the protective cover, and press home firmly.
- Install the expander nut (1) in the hole
- Thread the accompanying cable (2), including the ground cable, through the hole
- Assemble the connecting cable (3) from the kit with the expander nut cable. Turn clockwise so that the expander nut expands
- Remove the connecting lead.
Note! Ensure that the front intake drain is open.
- Apply heat conducting compound (P/N 9499205) to the surfaces (1) of the heater body in contact with the cylinder block.
- Jack up the car
- Remove the screw (1) in the left front brake air baffle (2)
- Pull the baffle backward to remove
- Remove the right front brake air baffle in similar manner.
- Slacken the screws (1) and remove the air baffle (2)
- Slacken the screws (3) and remove the guard plate (4).
Ground connection for cable under member
- Drill a 4 mm (5/32") hole
- Apply rust protection and connect the ground cable using the 4.8 mm (3/16") flanged screw and serrated washer supplied.
Note! Connect the ground cable to the side member, not to the subframe.
- Tie up excess cable using new tie clips.
Fig. A
- Clean the heater location to ensure the best possible transfer of heat to the cylinder block. Also clean the internal thread
- Slide the heat shield over the heater cable
- Take the sealing sleeve and heater cable from the kit. Connect the cable to the heater and fit the sleeve over the joint in the cable
- Mount the heater on the cylinder block as illustrated
- Fit the spacer (1) (t = 10 mm / 25/64") between the clamp (2) and bracket (3) on the cylinder block
- Fit the outer spacer (4) (t = 32 mm / 1 1/4") to the outer side of the clamp (2)
- Tighten the heater in position using the screw supplied. Torque to 16 Nm (12 lbf.ft.).
Fig. B
- Pull the heat shield all the way up to the heater so that the joint and plastic moulding are covered completely.
Note! It is important that the heat shield covers the entire joint with the engine.
- Secure the heat shield around the heater cable using a gray, heat-resistant tie clip around the bottom of the shield.
Applies when heater only is installed
- Remove the existing nut from the steering box
- Fit the bracket for mounting a branch connector and cables
- Fit the locknut from the kit and torque to 48 Nm (36 lbf.ft.)
- Attach the first tie clip to the power steering line. In the absence of a servo fluid cooling line, drill out the first hole to 6.5 mm (1/4") and attach the tie clip as normal.
Note! Cables must not be attached to drive shafts, or to A/C, fuel or brake lines. Ensure that clipped cables are not rubbing against sharp edges, or are not positioned too close to a turbo or exhaust pipe due to the risk of heat radiation.
Applies when both engine heater and in-vehicle outlet are installed
- Mount the branch connector on the bracket using screws and nuts from the kit
- Lubricate the O-rings with low-temperature grease (P/N 1161427)
- Connect the cables from the front intake (1), in-vehicle outlet (3) and engine heater (2) to the branch connector
- Torque the branch connector and bracket on the steering box to 48 Nm (36 lbf.ft.).
Applies to engine heater as illustrated
- Run the cable from the bumper to the heater cable as illustrated
- Secure the cable with tie clips using the existing holes and the oil cooler lines
- Connect the cable from the bumper to the heater cable or to the branch connector.
Note! Cables must not be attached to drive shafts, or to A/C, fuel or brake lines. Ensure that clipped cables are not rubbing against sharp edges, or are not positioned too close to a turbo or exhaust pipe due to the risk of heat radiation.
- Fit sealing sleeves over all cable connectors and joints, ensuring that these are correctly located.
- Refit the air baffles and guard plate as per items 6 and 7
- Torque screws to 80 Nm (60 lbf.ft.), and screws and nuts to 60 Nm (43 lbf.ft.)
- Secure the servo hose to the cross strut using a tie clip from the kit.