Electric Engine Block Heater
Electrical engine block heater, petrol 5 cyl
Electrical engine block heater, petrol 5-cyl. 230V
Installing the front engine block heater socket
- Clean the bumper cover. Use a mixture of 30% windscreen washer fluid and 70% water. Clean where the cutting template for the front engine block heater socket is to be secured
- Wipe dry.
- Apply a piece of tape vertically to the bumper cover. See the illustration.
- Remove the backing tape on the template from the kit
- Press the template onto the embossing on the bumper cover. The marking (1) on the template must be opposite the front edge of the tape. The marking (2) on the template must be in line with the curve (3) at the top edge of the embossing on the bumper cover.
- Take a sharp knife. First make a thin cut along the edges of the inside of the template. This provides a groove to follow. Then carefully cut out the bumper cover.
Note! Cut carefully. It is easy to slip with the knife and move outside the template.
- Remove the template
- Install the protective cover for the front engine block heater socket from the kit. Check that it fits. Adjust the hole using a knife or file as necessary
- Smooth off the hole edges. Remove any swarf.
- Remove the seven screws holding the engine splash guard in place. Remove the engine splash guard.
- Remove the left and right-hand front wheels
- 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.
- Press the protective cover (from the kit) into place in the hole cut in the bumper cover
- Insert the cable for the front engine block heater socket together with the ground lead from the kit through the protective cover.
Illustration A
- Install the mounting and nut from the kit. Connect the connector to the front engine block heater socket. Use the connector as a counterhold when tightening.
Illustration B
- Turn the connector for the front engine block heater socket so that the cover opens forwards. Tighten the front engine block heater socket to the bumper cover.
Cable routing
- Install three clips from the kit on the panel edge on the underside of the left front member.
- Reinstall the bumper cover. Use the five clips and the two screws at the top. Ensure that the air baffle is correctly positioned in its mounting
- Connect the connectors for the fog lamps if applicable
- Press the ends of the bumper cover into place on the body
- Route the cable for the front engine block heater socket from the front edge of the washer reservoir, along the underside of the front member and over the drive shaft. Insert the cable a little way into the engine compartment
- Press the cable into the previously installed clips
- Clamp the cable to the brake pipe. Use the double clamp (1) from the kit.
- Take a double clamp like the one used in point 14 from the kit. Clamp the cable at the lower of the two horizontal brake pipes at the upper edge of the cowl panel.
- Clamp the cable in the hole in the bracket for the front left radiator mounting. Use a tie strap (1) from the kit.
- Drill a 4 mm (5/32 ") diameter hole for the ground lead, on the outside of the left-hand front member, approximately as illustrated
- Treat the edges of the holes using a rust-proofing agent.
- Secure the ground lead in the drilled hole. Use the screw and toothed washer from the kit
- Secure the excess ground lead in the existing clips.
- 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. Insert the cable at point (1). Route the cable through the engine compartment (behind the AC pipes) down to the strut at the mounting for the right-hand control arm.
Illustration B
- Clamp the cable into place from the top of the engine compartment and downwards. Use a tie strap (illustration B) and double clamp (illustration C) at the existing cables and pipes.
Note! The cable must not be secured to the fuel lines, air conditioning (A/C) pipes or brake pipes.
Illustration C
- Grease the O-rings on all the engine block heater cables. Use low temperature grease (P/N 1161417-9). If the car is to have a passenger compartment connector socket/junction connector/timer relay, also grease the O-rings on these components.
Note! Do not get any grease on the contact surfaces of the connector.
Applies to cars where the engine block heater and passenger compartment connector socket are mounted at the same time
- Take the bracket and the rubber guard from the kit for the passenger compartment connector socket. Press the rubber guard on to the bracket.
Applies to cars where the engine block heater and passenger compartment connector socket are mounted at the same time
- Tighten the junction connector at the bracket (included in the kit for the passenger compartment connector socket) in the position illustrated. Use the screw, thrust washer and nut from the kit. The bracket must be parallel to the length of the junction connector
- Position (1) cable for the engine block heater
- Position (2) cable for the passenger compartment connector socket
- Position (3) cable from the front engine block heater socket.
Applies to cars where the engine block heater and timer relay are mounted at the same time
- Tighten the timer relay at the bracket (purchased separately) in the position illustrated. Use the screw, thrust washer and nut from the kit. The bracket must be parallel to the length of the timer relay
- Connect the connector on the long cable harness from the kit to the timer relay
- Press the rubber plug (1), P/N 346509, (purchased separately) into place on the free socket in the timer relay. Use butyl tape to secure the rubber plug
- Position (2) cable for the engine block heater
- Position (3) cable from the front engine block heater socket.
Applies to cars where the passenger compartment connector socket and timer relay are mounted at the same time
- Tighten the timer relay at the bracket (purchased separately) in the position illustrated. Use the screw, thrust washer and nut from the kit. The bracket must be parallel to the length of the timer relay
- Connect the connector on the long cable harness, from the kit, to the timer relay
- Position (1) cable for the passenger compartment connector socket
- Position (2) cable for the engine block heater
- Position (3) cable from the front engine block heater socket.
- Connect the short cable, from the engine block heater kit, to the cable (1) routed from the front engine block heater socket. (If installing the junction connector / timer relay at the same time, the cable from the front socket is connected to the same output on the junction connector / timer relay instead. See the installation instructions for the passenger compartment connector / timer relay)
- Firmly press the cable junction together.
- Press a locking sleeve (from the kit) over the cable junction.
- Take a double tie strap from the kit. Install the double tie strap around the strut and the cable junction. Ensure that the junction is secured in the centre of the strut. Tighten the double clamp properly.
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.
Illustration A
Illustration B
- Take the heater, the rubber-covered clamp, the bracket, and the self tapping screw from the kit. Assemble as illustrated. The short pipes (1) for the heater must be at right-angles to the long side of the bracket (see illustration B). Ensure that the short pipes for the heater are centered in relation to the cut-outs (2) in the bracket where the heater will be screwed into place
- Do not fully tighten the rubber clamp yet.
- Take two heater hoses and four hose clamps from the kit
- Install the two hoses on the heater with the shortest hose at the top
- Tighten the hoses to the heater in the positions illustrated. Use the hose clamps.
- Position the two remaining hose clamps on the hoses for the heater. See the illustration.
- Move the heater into position behind the oil cooler. Press the heater hoses into the terminals in the oil cooler and pipes for the oil cooler
- Take the three self tapping screws and three spacers from the kit. Tighten the bracket and heater to the rear edge of the oil sump.
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.
- Tighten the two loose hose clamps. Adjust the position of the heater connector so that it does not catch on the power steering hose or charge air hose
- Fully tighten the heater to the bracket.
- Connect the previously routed short cable (1) 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.
Illustration A
Illustration B
- The cable between the engine block heater and the splice on the stay for the sub-frame has a certain amount of excess which must be clamped up. Take the double clamp and tie strap from the kit. Clamp the excess cable as shown in illustrations A and B.
- 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
- Reinstall the engine splash guard
- Reinstall the front wheels. Tighten the wheel nuts. Tighten to 90 Nm (66 lbf. ft.).