Electrical engine block heater, 230V, 5 cyl AWD

• Use isopropanol P/N 1161721 to clean the bumper shell 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.

• Remove the seven screws from the engine splash 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 four screws.

• Push in the centre of the five clips (1). Remove the clips.
• Remove the two screws (2).

• 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.

• 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 and parking assistance if applicable.

• Cut out the template by cutting along the outer edges of the dotted and solid line.
• place the template with the dotted section on the existing marking (periphery) on the bumper. Mark according to the new, slightly recessed marking.
• Cut off the upper dotted section of the template and finish the new marking all the way around.

• Using a sharp knife, first make a thin cut along the edges of the new marking inside of the bumper cover. Then carefully cut out the bumper cover hole.

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

• Take the protective cover from the kit and press it into the hole cut in the bumper cover.
• Take the cable for the front intake with ground lead from the kit and thread them through the protective cover.

• 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.

• Turn the front intake connector so that the cover opens forwards.
• Tighten the front engine block heater socket to the bumper shell.

• 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.
• Reconnect the connectors for the fog lamps and parking assistance if applicable.
• 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 Ø4 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 part no. 1161417). 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), part no. 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.

• Remove the screw from the bevel gear.
• Install the bracket from the kit using M10 screws. Tightening torque 50 Nm.

• Take the heater, rubber coated clamp, hoses and hose clamp from the kit. Assemble as illustrated.

• Connect the heater between the oil cooler and water pipe. Tighten the clamps securely.

• Secure the heater to the bracket using screws from the kit.

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

• Route the cable as illustrated.
• Connect the cable to the engine block heater. Press it into the engine block's connection securely.
• Press in a locking sleeve from the kit over the cable splice (1).
• Pull the radiation shield up so that it fully covers the connector on the heater.
• Fasten the radiation shield at the heater connection (2) using the gray tie strap.

• Take two double clamps from the kit and clamp the cable in the power steering hoses.

• 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 wheels and tighten the wheel bolts to 90 Nm (66 lbf.ft.).