Part 3

Electric engine block heater, 230V, 5 cyl



















































INTRODUCTION
- NOTE! Read through the whole installation instruction before starting the work.
- The illustrations display the procedure in order of operation. The order of operation is repeated in the text






Illustration A




- Press the front intake cable into the clips. Guide down the cable at point (1) and route down through the engine compartment (behind the AC pipes) down to the strut in the right link arm mounting.

Illustrations B and C




- Clamp the cable from the top of the engine compartment and down using a tie strap (Illustration B) and double clamp (Illustration C) at existing cables and pipes.

Note! Do not clamp the cable directly to AC pipes, fuel lines, brake pipes or power steering hoses and pipes. Make sure the cable does not chafe against sharp edges or moving parts in the engine compartment.









- Lubricate the O-rings on all cables for the engine block heater and if the car is to have a passenger compartment connector/timer relay, also lubricate the O-rings on these with low temperature grease P/N 1161417.

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






Applies to cars where the engine block heater and passenger compartment connector socket are installed 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 installed 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, toothed 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 socket
- Position (3) cable from the front engine block heater socket.






Applies to cars where the engine block heater and timer relay are installed at the same time
- Tighten the timer relay at the bracket (purchased separately) in the position illustrated. Use the screw, toothed 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), part no. 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 the timer relay are installed at the same time
- Tighten the timer relay at the bracket (purchased separately) in the position illustrated. Use the screw, toothed 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 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 kit to the engine block heater, to the routed cable (1) from the front socket. (When fitting junction connector/timer relay at the same time, the cable from the front socket is connected to the single outlet on the junction connector/timer relay instead. Refer to the installation instructions for passenger compartment socket/timer relay).
- Firmly press the cable junction together.





- Press a locking sleeve (from the kit) over the cable splice.





- Take a double tie strap from the kit. Install the double tie strap around the stay and the cable splice. Ensure that the splice 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 drive shaft. Drain the coolant.





- Detach the hose clips of the left oil cooler hose and remove the hose.
- Put the hose to the side.





- Take a bracket, two bolts and washers from the kit. Fasten the bracket in the existing holes on the left side of the oil cooler.

Note! The screws are self-tapping so it may be slow inserting them. Make sure that the screws are centered straight into the holes, so that the screw heads are flat against the bracket.





- Take the heater, rubber-clad clamp and bolt from the kit. Fasten the heater with the clamp. The connections should point straight back.





- Take the long hose and two hose clips from the kit. Connect the hose between the radiator pipe and upper heater socket.
- Tighten the hose clips.






Applies to cars with diesel engine
- Cut the remaining hose 15 mm (19/32") in the long, straight end.





- Take the hose and two hose clips from the kit and connect them between the oil cooler and lower heater socket. The end with the long, straight/cut part should be connected to the oil cooler (see previous illustration).
- Tighten the hose clips.





- Take the radiation shield from the kit and thread on the joint cable of the heater.





- Connect the short electrical cable (which was routed earlier) to the engine block heater. Press it firmly into the engine block heater connection.
- Press in a locking sleeve from the kit over the cable splice.





- Pull the radiation shield up so that it fully covers the connector on the heater.
- Take the grey tie strap kit and clamp the radiation shield by the heater in the upper edge.


Illustration A applies to the diesel engine




- Fasten the heater cable to the turbocharger pipe using a double tie strap from the kit.

Illustration B applies to Petrol engines without turbo




On cars with Petrol engine without turbo, route the cable with radiation shield below the power steering hoses/pipes.
- Fit a double tie strap to the two steering gear pipes and the cable with radiation shield.
- Fit the double tie strap over the hoses' press sleeves.

Illustration C applies to Petrol engine with turbo




On cars with Petrol engine and turbo, route the cable with radiation shield under the power steering hoses/pipes and under the turbo pipe.
- Fit a double tie strap to turbocharger pipe and the cable with radiation shield.
- Fit a double tie strap to the cable and the left power steering pipe.

- Reinstall the left-hand fender liner. Tighten the fender 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 and check that there are no leaks.
- Reinstall the engine splash guard.
- Reinstall the front wheels and torque tighten the wheel nuts:
Step 1: Wheel to wheel hub, 20 Nm
Step 2: Wheel to wheel hub, 110 Nm