Electric engine heater

• Remove the bumper guard. Loosen the guard at one end using a thin plastic blade and pull it off.

• Cut a hole (1) in the bumper guard as marked at the rear of the strip. Use a carpet knife or similar tool and allow a certain margin.

Примечание: When cutting along the upper horizontal line, lean the knife against the upper edge of the strip as a guide to ensure that the cut is precisely in the middle of the rounded section.
- Smooth the edges of the hole with a file.

• Fit the protective cover (1) for the front intake in the bumper guard
• Place the guard in position but do not secure at this point
• Mark out the hole in the bumper cover (2) with the aid of a 29 mm (1 1/8”) hole saw and centre bit
• Remove the bumper guard and protective cover and cut the hole with the same hole saw.Ø29 mm (11/8”)
• Remove the swarf
• Refit the bumper guard, with the protective cover, and press home firmly.

• Install the expander nut (1) in the hole
• Thread the accompanying cable (2), including the ground cable, through the hole
• Assemble the connecting cable (3) from the kit with the expander nut cable. Turn clockwise so that the expander nut expands
• Remove the connecting lead.

Примечание: Ensure that the front intake drain is open.

• Apply heat conducting compound (P/N 9499205) to the surfaces (1) of the heater body in contact with the cylinder block.

• Jack up the car
• Remove the screw (1) in the left front brake air baffle (2)
• Pull the baffle backward to remove
• Remove the right front brake air baffle in similar manner.

• Slacken the screws (1) and remove the air baffle (2)
• Slacken the screws (3) and remove the guard plate (4).

Ground connection for cable under member

• Drill a 4 mm (5/32") hole
• Apply rust protection and connect the ground cable using the 4.8 mm (3/16") flanged screw and serrated washer supplied.

Примечание: Connect the ground cable to the side member, not to the subframe.
- Tie up excess cable using new tie clips.

Fig. A

• Clean the heater location to ensure the best possible transfer of heat to the cylinder block. Also clean the internal thread
• Slide the heat shield over the heater cable
• Take the sealing sleeve and heater cable from the kit. Connect the cable to the heater and fit the sleeve over the joint in the cable
• Mount the heater on the cylinder block as illustrated
• Fit the spacer (1) (t = 10 mm / 25/64") between the clamp (2) and bracket (3) on the cylinder block
• Fit the outer spacer (4) (t = 32 mm / 1 1/4”) to the outer side of the clamp (2)
• Tighten the heater in position using the screw supplied. Torque to 16 Nm (12 lbf.ft.).

Fig. B

• Pull the heat shield all the way up to the heater so that the joint and plastic moulding are covered completely.

Примечание: It is important that the heat shield covers the entire joint with the engine.
- Secure the heat shield around the heater cable using a gray, heat-resistant tie clip around the bottom of the shield.

Applies when heater only is installed

• Remove the existing nut from the steering box
• Fit the bracket for mounting a branch connector and cables
• Fit the locknut from the kit and torque to 48 Nm (36 lbf.ft.)
• Attach the first tie clip to the power steering line. In the absence of a servo fluid cooling line, drill out the first hole to 6.5 mm (1/4") and attach the tie clip as normal.

Примечание: Cables must not be attached to drive shafts, or to A/C, fuel or brake lines. Ensure that clipped cables are not rubbing against sharp edges, or are not positioned too close to a turbo or exhaust pipe due to the risk of heat radiation.

Applies when both engine heater and in-vehicle outlet are installed

• Mount the branch connector on the bracket using screws and nuts from the kit
• Lubricate the O-rings with low-temperature grease (P/N 1161427)
• Connect the cables from the front intake (1), in-vehicle outlet (3) and engine heater (2) to the branch connector
• Torque the branch connector and bracket on the steering box to 48 Nm (36 lbf.ft.).

Applies to engine heater as illustrated

• Run the cable from the bumper to the heater cable as illustrated
• Secure the cable with tie clips using the existing holes and the oil cooler lines
• Connect the cable from the bumper to the heater cable or to the branch connector.

Примечание: Cables must not be attached to drive shafts, or to A/C, fuel or brake lines. Ensure that clipped cables are not rubbing against sharp edges, or are not positioned too close to a turbo or exhaust pipe due to the risk of heat radiation.

• Fit sealing sleeves over all cable connectors and joints, ensuring that these are correctly located.

• Refit the air baffles and guard plate as per items 6 and 7
• Torque screws to 80 Nm (60 lbf.ft.), and screws and nuts to 60 Nm (43 lbf.ft.)
• Secure the servo hose to the cross strut using a tie clip from the kit.