Electric engine block heater, 5-cyl. 230V

• 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 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 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 the protective film along the outside of the bumper's left-hand corner.

• 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.

• Press in the centre of the clips (1) and remove them. Remove the screws (2).

• 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.

• Detach the right and left-hand ends 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.

Подсказка: Removal of the bumper is facilitated if carried out by two people.

• Unscrew and remove the bolt and nuts securing the wing liner.
• Remove the wing liner.

• Remove the screws holding the engine splash guard and remove the guard.

• Locate the pre-marking on the inside of the bumper cover on the left-hand side of the car.
• Use a Ø10mm (3/8") drill bit to drill inside the four corners of the pre-marking.
• Take a sharp knife and carefully cut out the pre-marked area in the bumper cover on the left-hand side of the car.

Примечание: Cut carefully. It is easy to slip with the knife and move outside the markings.

• Remove swarf and smaller irregularities with a file. Do not damage the paintwork and follow the pre-marking accurately.
• Install the box for the front engine block heater socket from the kit. Check that it aligns. Adjust the hole using a knife or file as necessary.
• File down the edges of the holes.

• Take the cable harness with front socket and box from the kit.
• Route the cable through the box and fit the connector.
• Pull in the cable and align the box in the hole made in the bumper.

• Take the bracket and the large plastic nut from the kit and thread the cable harness through them.
• Pull forward the bracket to the inside of the bumper and tighten the box with the large plastic nut. Plug the electrical connector into the front socket as a counterhold for when the latter is tightened.

• Check that the connector cover works as intended.

• 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.
• Press in so that the clips under the headlamps fasten.
• Reinstall the connectors for the fog lamps if fitted.
• Press the ends of the bumper cover into place on the body.

Подсказка: Installation of the bumper is facilitated if carried out by two people.

• Install three clips from the kit on the panel edge on the underside of the left front member.

• Route the front intake cable from the front edge of the washer fluid reservoir, along the bottom edge of the front member and over the drive shaft. Route the cable a bit into the engine compartment.
• 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 double clamp from the kit (similar to the previous step). Clamp the cable at the lower of the two horizontal brake pipes in the top edge of the bulkhead.

• 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.
• 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.
• Affix the excess length of ground lead at the existing clips.

• Install three clips from the kit on the front edge of the panel above the windscreen wiper motor.
• Guide the cable up to the top of the engine compartment to the position illustrated.

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 stay 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.

Примечание: 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.

• Grease the O-rings on all the engine block heater cables using 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.

Примечание: 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.

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 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.

• 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.

Примечание: The screws are self-tapping so it may be slow inserting them. Make sure that the screws are centred 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 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.
• 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.
• Remount the front wheel and tighten the wheel bolts to 90 Nm (66 lbf.ft.).