Electric Engine Block Heater 110V

Electric engine block heater 110V





























Electric engine block heater, 110V

Preparations




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




- Press the catch up. Remove the cover. Do not damage the painted surfaces or the washer nozzles.




- Remove the screws to the air baffle.




- Push in the center of the clips (1). Remove the clips.
- Remove the screws (2).




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




- Detach the right and left-hand end faces of the bumper.
- Grip the bumper from the inside and pull it forward in order to detach the two holders under the headlamps.
- Remove the bumper, unplug the connectors for the fog lamps and place the bumper on a surface that does not damage the paintwork.

Note! Removal of the bumper is facilitated if carried out by two people.





Remove:
- the nuts
- the screw
- the left-hand wing liner.




- Remove the screws and the engine splash guard.

Installing the front connector.




- Cut out a hole in the bumper cover grille.




- File away any irregularities.




- Take the cable harness and thread on the protective cap's eyelet.




- Install the front connector in the mounting.




- Lift the mountings at the back in order to lock the front connector.




- Install the attachment plate in the front connector with the screw and nut. Do not tighten too hard, it must be possible to guide the connector into the mounting.




- Cut away the three rectangular studs on the attachment plate.




- Route the cable harness through the hole in the grille so that the front connector is in contact with the grille.




- Cut away any protrusions on the grille where the spacer washer shall be located.
- Secure the front connector from the inside with a screw and spacer washer.




- Check the function. Install the protective cap on the front connector.





Reinstall:
- the air baffle
- the bumper. Make sure that the air baffle is positioned correctly in its mounting against the bumper. Press on so that the catches under the headlamps attach.
- the five clips and the screws in the top edge.
- the connectors to the fog lamps.

Note! Installation of the bumper is facilitated if carried out by two people.

Cable routing




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




- Remove the air baffle in front of the engine splash guard in order to gain access to insert the cable between the front grille's left-hand side end face and the seal in front of the radiator.
- Route the front connector cable by the seal at the lower front grille's left-hand side end face. Route it on the top of the radiator's left-hand bracket (1) and up to the lower edge of the side member. Route it along the lower edge of the front member and over the drive shaft. Guide the cable up slightly in the engine compartment.




- Press the cable into the previously installed clips.
- Clamp the cable into the brake pipe with a double clamp (1).
- Reinstall the air baffle in the bumper cover and to its rear mounting in the bracket, in the lower edge of the radiator.




- Locate the cable as illustrated, and clamp it in on the subframe bracket using a tie strap.




- Install three clips with tie straps on the front edge of the panel under the windscreen wipers.
- Guide the cable up to the top of the engine compartment to the position illustrated.




- Install the front socket cable using tie straps.
- Guide the cable down at point (1) and route it through the engine compartment (behind the AC pipes), down to the right-hand link arm's mounting.




- Clamp in the cable, from the top of the engine compartment and down, using a tie strap.

Note! The cable must not be clamped directly to AC, fuel or brake pipes.




- Clamp in the front socket cable at the top of the subframe bracket using a tie strap.




- Grease the O-ring on the front socket's cable with low temperature grease (P/N 1161427).

Note! There must be no grease on the connector pins.

Installing the engine block heater




- Remove the cap on the cooling system expansion tank.
- Install a hose on the engine block drain nipple. Open the nipple and drain the coolant into a collection container.
- Close the nipple and remove the hose.




- Remove the clamps and radiator hose from the radiator pipe and the oil cooler. They shall not be re-used.

Illustration A




- Install the engine block heater on the bracket with a rubber coated clamp and screw, in the position as illustrated. Do not tighten the screw yet.

Illustration B




- The engine block heater's short pipes must be at right-angles to the long side of the bracket.

Illustration C




- Make sure that the distances between the short pipes and the bracket are equal.




- Take two short heater hoses and four hose clamps from the kit. Install the two hoses to the engine block heater with the shortest hose on top.
- Tighten the hoses to the engine block heater using the hose clamps located as illustrated.




- Fit the two remaining hose clamps onto the engine block heater hoses as illustrated.




- Guide the engine block heater up into position behind the oil cooler. Install the engine block heater's hoses on the outlet and the pipe for the oil cooler.
- Take the three self-tapping screws and the three spacer washers from the kit. Tighten the bracket with the engine block heater into the rear edge of the oil sump.

Note! The screws are self-tapping so it may be difficult to screw them in. Make sure that the screws are centered straight in the holes.




- Tighten the two loose hose clamps and adjust the position of the engine block heater connector so that it does not make contact with the servo hose, charge air hose or drive shaft.
- Tighten the engine block heater firmly to the bracket.




- Take the deflector hose from the kit and thread it onto the routed cable as far as possible. The deflector hose may need to be cut slightly to fit. It must cover the cable from where it is clamped at the right-hand strut, up to and including the connector to the engine block heater.




- Press in a locking sleeve over the cable splice.




- Pull the deflector hose down over the engine block heater's connector. Take a grey tie strap from the kit and tighten it into the lower edge of the deflector hose.

- Reinstall the left-hand wing liner. Tighten 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.
- Refit the covers to the nozzles for the headlamp high-pressure washers.
- Fill with coolant, run the engine to operating temperature, bleed the cooling system and check that there are no leaks.
- Reinstall the engine splash guard.
- Refit the front wheel. Torque tighten the wheel nuts alternately to 90 Nm (66 ftlb.).