Electrical 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 fits. Adjust the hole using a knife or file as necessary
- Smooth off the hole edges. Remove any swarf.

• Remove the 7 x screws holding the engine splash guard in place. Remove 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 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 cover for the headlamp high-pressure cleaning nozzles 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 high-pressure cleaning 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 fog lamp connectors if such are fitted.

• 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. Ensure that the air baffle is correctly positioned in its mounting
• Reconnect the fog lamp connectors if such are fitted.
• Press the ends of the bumper cover into place on the body
• Draw the front socket lead from the front edge of the cover to the control unit, along the bottom of the front member and over the drive shaft.
• Press the cable into the previously installed clips
• Clamp the lead in place at the brake pipe using the double clamp (1) from the kit.

• Take a clip from the kit and press it into place at the plate edge as illustrated.
• Press the lead into the clip.

• Clamp the electrical lead in the hole in the bracket to the left lower radiator mounting using a tie strap (1) from the kit.

• Drill a Ø4 mm (5/32”) diameter 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 length of the ground lead at the clamp to the heater's lead.

• Remove the cover on the radiator expansion tank
• Unscrew the drain nipple on the bottom left edge of the radiator and drain the coolant.

• Remove the protective cover from over the engine by pulling it straight up until it releases from the three rubber mountings on the underside.

Illustration A

• Remove the four screws of the heat deflector plate over the manifold.

Illustration B

• Bend aside the heat deflector plate from the left side of the manifold.

Примечание: Exercise care with the lead to the heated oxygen sensor.
- Unplug the connector of the heated oxygen sensor as necessary.

• Remove the plug in the engine block below the left side of the manifold using a hexagonal socket, part no. 9512965.

Примечание: There is a small amount of coolant left in the engine.

• Take the heater from the kit and brush sealing compound, part no. 1161056, on the threads.
• Tighten the heater in the engine block hole using a spanner, part no. 9997158. Angle it so that it does not touch the gearbox mounting flange on the engine.

• Grease the O-rings on all engine block heater leads and, if the vehicle is to have a cabin contact/branch contact/timer relay, grease the O-rings on these as well with low temperature grease (part no. 1161417-9).

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

• Connect the lead (1) from the kit to the engine block heater.
• Press the lead joint securely together. Press a locking sleeve from the kit over the lead joint. Make sure the lead is not chafed against sharp edges or moving parts in the engine compartment.

• Take the heat deflector sock from the kit and cut it to a length of 200 mm (7 7/8").
• Fit the heat deflector sock on the lead up to the heater so that it covers the entire contact on the heater.
• Take the grey tie strap (1) from the kit and clamp the top edge of the heat deflector sock.

• Draw the lead (1) from the engine block heater over the gearbox and up to the drive shaft where the front socket lead (2) is located.
• Press a clamp (3) from the kit onto the edge of the bracket of the shift cables.
• Press the lead into the clamp.

Applies to vehicles where the engine block heater and/or cabin contact/timer relay 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 mounted 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, thrust 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 mounted at the same time

• Tighten the timer relay at the bracket (purchased separately) in the position illustrated. Use the screw, thrust 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), on the empty recess in the timer relay. Use butyl tape to ensure the rubber plug fits securely.

Applies to cars where the passenger compartment connector socket and timer relay are mounted at the same time

• Tighten the timer relay at the bracket (purchased separately) in the position illustrated. Use the screw, thrust 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 lead from the engine block heater kit to the lead (1) routed from the front socket (if the branch contact/timer relay is installed at the same time, the lead from the front socket is connected to the lone socket on the branch connector/timer relay instead. See installation instructions for cabin contact/timer relay).
• Firmly press the cable junction together.

• Press a locking sleeve (from the kit) over the cable junction

• Take a double tie strap from the kit. Install the double tie strap around the strut and the cable junction. Ensure that the junction is secured in the centre of the strut. Tighten the double clamp properly.

Bleeding and charging the cooling system Illustration A

• Fit the adapter, part no. 9512955, in the expansion tank and tighten.

Illustration B

• Fit the bleeding kit, part no. 9512957, on the adapter's connection nipple.

Illustration C

• Bleed and charge the cooling system following the bleeding kit manual.

• Refit the heat deflector plate and tighten the screws to 10 Nm (7 lbf.ft).
• Reinstall the left-hand wing liner. Secure 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 for the high pressure headlamp washing nozzles.

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