Electric engine block heater, Diesel

• Remove the front and rear engine splash guards.

• Stick the drill template in position as illustrated
• First drill two holes. Use a 4 mm (5/32”) diameter drill bit. Then drill a 29 mm (1 9/64”) diameter hole. Use a hole saw. File down the edges.

• Install the expander nut (1) in the hole
• Thread the supplied cable (2), including the ground lead, down through the hole
• Connect the connector cable supplied (3) to the cable at the expander nut. Tighten clockwise so that the expander nut secures
• Remove the connection cable.

Примечание: Ensure that the drainage hole for the front engine block heater socket is open.

• Route the cable to the front end of the left-hand front member
• Route the cable backwards, underneath the front member to the cross member mounting
• Secure the cable using the four clips from the kit.

• Remove the bracket positioned on the rear section, on the inside of the left-hand front side member
• Install the new bracket from the kit, on the outside of the removed bracket as illustrated. Tighten the brackets.

• Lubricate the O-ring using low temperature grease, (P/ N 1161427).

• Connect the cable to the joint cable from the kit
• Install the retaining clip
• Secure the joint cable in the previously installed bracket. Use a tie strap from the kit.

• Drill a 4 mm (5/32") diameter hole in the front edge on the left-hand front member behind the existing hole
• Scrape away the paint around the hole
• Treat the edges of the holes using a rust-proofing agent
• Install the ground lead with the screw (1) and the toothed washer (1) from the kit.

• Remove the engine splash guard (x3 bolts).

• Remove the expansion tank cover
• Open the radiator drain nipple. Drain off the coolant. (Collect the coolant in a container.)
• Close the radiator drain plug when the radiator is empty.

• Punch the centre of the right-hand core plug using a centre punch. Use puller (P/N 9814219) to remove the core plug
• Install the expander in the core plug. Tighten to 10 - 25 Nm (max 40 Nm) (7.5 - 19 lbf.ft., max 30 lbf.ft.).

Примечание: Tightening more than this may damage the expander.

• Install the mounting bracket. Remove the core plug.

• Lubricate the heater pad O-ring using engine oil
• Install the heater pad in the cylinder block. Turn the electrical terminal up to the position illustrated. Secure in the cylinder block using the tensioner and screw.Tighten the screw. Tighten to 18 Nm (13.5 lbf.ft).

• Route the cable from the bracket at the rear edge on the left-hand front member, around the power brake booster and along the cable harness by the cowl panel as illustrated.Secure the cable at the existing cable harness using tie straps from the kit all the way along the cowl panel to the right-hand side of the car.

• Thread the radiated heat shield from the kit on the engine block heater cable
• Apply low temperature grease on the O-ring for the connector. Press the connector securely into the engine block heater connector
• Press a locking sleeve from the kit over the joint.

• Pull down the radiated heat shield over the joint for the engine block heater cable
• Secure the radiated heat shield at the lower edge and the upper edge using a grey tie strap from the kit
• Secure the heater cable with the radiated heat shield at the power steering pipe using tie straps from the kit.Ensure that the heater cable is as far away as possible from the exhaust pipe at the turbocharger (TC).

Applies to all engines

• Fill the cooling system through the expansion tank. (Reuse the drained coolant if the car is new). The total coolant volume is approximately 4.5 litres.

• Bleed the cooling system by removing the bleed nipple on the hose for the heater pad. Tighten the nipple as soon as the coolant starts to seep out.

• Run the engine until the thermostat opens and top up if necessary
• Check for any leakage
• Check the function of the engine block heater.

Примечание: The engine block heater must only be connected to a grounded socket.
- The cable between the mini-connector and the 220 V socket must be made of oil-resistant rubber and must be RDO 3 x 1.5 mm2 or thicker. The connector socket must be water resistant and be made of thermoplastic. The cable must be treated with care so that it is not damaged by sharp objects.