Electric Engine Block Heater, 115V

Electrical engine block heater, 5 cyl. 115V
























Electrical engine block heater, 5-cyl. 115V

Preparations




- Remove the seven screws holding the engine splash guard in place. Remove the engine splash guard.




- 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. Clamp the cable at the bracket (1). Use a tie strap from the kit. 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 top of the strut. Use the tie strap from the kit. Slide the cable up to the top of the engine compartment.




- 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 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.

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.




- Take the protective sleeve from the kit. Thread the protective sleeve as far onto the pre-routed cable as possible. Cut the protective sleeve slightly if necessary. The sleeve must cover the cable from where it is clamped on the right-hand stay, up to and including the switch on the heater.




- Press a locking sleeve from the kit over the joint.




- Pull the protective sleeve down over the heater switch. Take a grey tie strap from the kit. Tighten at the lower edge of the protective sleeve.

- 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
- Reinstall the covers for the nozzles for the headlamp high-pressure washer
- 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.).