Electrical engine block heater, diesel, 4-cyl. D4204T 230V

• Turn the ignition key to position 0.
• Disconnect the battery negative lead.

• 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.

• Turn the seven clips 90°. Release the engine splash guard from the clips. Place the engine splash guard to one side.

• 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 connectors for the fog lamps if applicable.

• Press the protective cover (from the kit) into place in the cut out hole 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 connectors for the fog lamps if applicable.
• Press the ends of the bumper cover into place on the body.
• Route the cable for the front engine block heater socket from the front edge of cover for the control module, along the underside of the front member and over the drive shaft.
• 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 clip (1) from the kit. Press the clip into place at the edge of the panel. See the illustration.
• Press the cable into the clip.

• 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 4 mm (5/32 ”) diameter hole for the ground lead, on the outside of the left-hand front member, approximately as shown in the illustration.
• Treat the edges of the holes using a rust-proofing agent.

• Secure the ground lead in the drilled hole. Use the screw and thrust washer from the kit.
• Secure the excess ground lead at the clamp for the heater cable.

• Remove the cover on the radiator expansion tank.
• Unscrew the drain nipple in the left-hand bottom edge of the radiator. Drain the coolant.

• Pull up the front edge of the engine cover so that the three mountings (1) on the underside release.
• Pull the engine cover forwards until the mounting (2) on the underside releases. Remove the engine cover.

• Remove the front, large nut in the battery terminal on the starter motor.

• Remove the two upper screws for the starter motor.

• Remove the lower screw for the starter motor.

• Pull the starter motor out of its mounting in the engine. Turn the starter motor up so that the electrical connections become accessible.
• Remove the small nut and disconnect the last electrical connection.
• Remove the starter motor from the underside of the car.

• Disconnect the radiator hose from its clamp. Secure the radiator hose above the core plug.
• Punch the centre of the core plug on cylinder number two using a centre punch.
• Use puller P/N 9512960 to remove the core plug.
• Install the expander in the core plug and tighten.

Осторожно: Tighten to 10-25 Nm (7-18 lbf. ft.), max. 40 Nm (30 lbf. ft.). Tightening more than this may damage the expander.

• Install the mounting bracket. Remove the core plug.

Примечание: There may be some coolant left in the engine.

• Reinstall the radiator hose in its clamp.
• Remove the screw in the tensioner for the hose connector in cylinder number three.

• Lubricate the O-ring on the engine block heater using low temperature grease, (P/N 1161417-9).
• Press the engine block heater into place in the hole for the core plug, with the angled section of the heater element pointing down.
• Tighten the engine block heater to the engine block using the tensioner and the screw from the kit. (The tensioner is positioned above the existing tensioner).
• Tighten the screw. Tighten to 24 Nm (18 lbf. ft).

• 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 contact surfaces of the connector.

Illustration A

• Connect the cable (1) from the kit to the engine block heater.
• Firmly press the cable junction together. Press a locking sleeve from the kit over the cable junction. Ensure that the cable does not rub against sharp edges or moving parts in the engine compartment.

Illustration B

• Route the cable (1) from the engine block heater, over the gearbox where it is attached to the engine, and on to the drive shaft where the front engine block heater socket cable (2) is located.

Applies to cars where the engine block heater and/or passenger compartment connector socket/timer relay are mounted 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), 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 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 cable (1) from the engine block heater to the pre-routed cable (1) from the front engine block heater socket. (If installing the passenger compartment connector socket and the timer relay at the same time, the bracket and the mounting bracket with the junction connector/timer relay are installed at this point.)
• 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.

• Clamp the cable from the engine block heater to the brake pipe using a double clamp (1) from the kit. This is done to keep it away from the rear edge of the gearbox.

• Remove the sprung guide sleeve from the starter motor attachment flange in the gearbox.

• Install the guide sleeve in the starter motor attachment flange. Press in so that it bottoms in the hole.

Bleeding and filling the cooling systemIllustration A

• Install adapter P/N 9512955 in the expansion tank. Tighten.

Illustration B

• Install the bleed kit P/N 9512957 on the connection nipple for the adapter.

Illustration C

• Bleed and fill the cooling system. See the manual for the bleed kit.

• Reinstall the starter motor.
• Tighten the three M10 screws. Tighten to 35 Nm (26 lbf. ft).
• Tighten the M8 nut to the battery terminal. Tighten to 12 Nm (9 lbf. ft).
• Tighten the M6 nut to the battery terminal. Tighten to 6 Nm (4.5 lbf. ft).
• Reconnect the battery negative lead.
• 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.

• Reinstall the engine splash guard.
• Reinstall the front wheel. Tighten the wheel nuts. Tighten to 90 Nm (66 lbf. ft.).
• Reinstall the engine cover.