Electric engine block heater, 4-cyl

• 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 cut carefully out of the bumper cover.

Примечание: 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 aligns. 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 and remove the 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 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.

Illustration B

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

• 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 edge. Ensure that the air baffle is correctly positioned in its mounting.
• Reconnect 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 cover for the control module, along the underside of the front member and over the drive shaft.
• Press the cable into the previously installed clips.
• Clamp the cable to the brake pipe using the double clamp (1) from the kit.

• Take a clip from the kit. Press the clip into place at the edge of the panel. See the illustration.
• Press the cable into the clip.

• 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 ØØ4 mm (5/32) hole for the ground lead, on the outside of the left-hand front member, approximately as illustrated.
• Remove any swarf.
• 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 at the clamp for the heater cable.

• Grease the O-rings on all the engine block heater cables using low temperature grease (P/N 1161761). If the car is to have a passenger compartment connector socket/junction connector/timer relay, also grease the O-rings on these components.

Примечание: Do not get any grease on the surfaces of the connector.

• Connect the joint cable from the kit to the engine block heater.
• Firmly press the cable junction together. Press a locking sleeve from the kit over the cable junction. Ensure that the cable does not rub against sharp edges or moving parts in the engine compartment.

• Take the heat deflector hose from the kit and cut it to a length of 200 mm (7 7/8").
• Thread the heat deflector hose onto the cable right up to the heater, so that it covers the whole connector on the heater.
• Take the grey tie strap from the kit and clamp the upper edge of the heat deflector hose firmly.

• Pull the cable (1) from the engine block heater, over the gearbox and on to the drive shaft where the front socket cable (2) is located.
• Press in a clamp (3) from the kit at the edge on the bracket for the gear selector cables.
• Press the cable into the clamp.

Applies to cars where the engine block heater and/or passenger compartment connector socket/timer relay 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 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.

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), P/N 346509, (purchased separately) into place on the free socket in the timer relay Use butyl tape to secure the rubber plug.

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.

• Connect the short cable from 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.

• 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.
• Reinstall the engine splash guard.
• Reinstall the front wheel. Tighten the wheel nuts. Tighten to 90 Nm (66 lbf.ft.).