Engine block heater 230 V

• Secure the template sticker. Use the template to mark up the bumper for holes
• Drill a hole using a 4 mm (5/32") diameter drill bit
• Drill a hole at right-angles to the surface. Use a 29 mm (1 1/8") diameter hole saw
• Adjust the guide hole using a round file
• Also adjust the lead-in hole if necessary.

• Open the drain holes on both sides. Use a screwdriver and press in by hand at the markings.

• Install the expander nut in the hole, with the locating pin in the guide hole
• Route the cable, including the ground lead, from the front socket from above and downwards. Let the cables hang down to the ground.

• Connect the cable to the front engine block heater socket
• Press downwards and turn the cable clockwise so that the expander nut engages
• Align the cable from the front socket so that the hinge is pointing towards the headlamp
• Remove the connection cable.

• Raise the car
• Remove the screw (1) from the left air baffle (2) for the front brake
• Pull the left air baffle backwards. Remove the left air baffle
• Remove the right air baffle in the same way.

• Remove the screws (1)
• Press in the catches (5) and pull the air baffle (2) down/backwards. Remove the air baffle
• Remove the screws (3). Remove the splash guard (4).

• Route the cable for the front engine block heater socket together with the ground lead on the left-hand side of the side member
• Drill a hole using a 4 mm (5/32") diameter drill bit
• Rust-proof and secure the ground lead using the 4.8 mm (3/16") diameter flanged screw and toothed washer included.

Примечание: Connect the ground lead to the side member, not to the sub-frame.

• Secure any excess ground lead using a tie strap from the kit.

• Remove the draining nipple on the hose to the left of the oil cooler. Drain the coolant
• Remove the clamps (1) on the lower hose on the oil cooler. Remove the hose. Place the hose to one side. This will not be used again.

• Install the hoses (from the kit) on the heater. Align the white markings (1) with each other as illustrated.

• Remove the screw (1) in the bottom cover on the right front corner of the gearbox
• Tighten the small bracket (from the kit) using the screw to the gearbox as illustrated. Tighten the screws. Tighten to 10 Nm (7 lbf.ft.).

• Position the four hose clamps (from the kit) on the hoses and heater
• Tighten the hose clamp (1). Position the hose clamp (2) as illustrated. Tighten the hose to the oil cooler.

• Position the rubber coated clamp (1) (from the kit ) on the heater as illustrated.

• Install the heater with the hoses to the oil cooler pipe
• Take a blind rivet (1) from the kit. Blind rivet the rubber coated clamp with the heater to the bracket in the bottom cover of the gearbox
• Tighten the remaining hose clamps to the heater and oil cooler pipe.

• Route the extension cable (from the kit) over the right-hand front corner of the sub-frame.

• Lubricate the O-ring on the extension cable connector using low temperature grease, (P/N 1161417-9).

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

• Connect the extension cable to the engine block heater
• Press a locking sleeve (from the kit) over the cable splice
• Tighten the cable as illustrated. Secure the cable using a tie strap from the kit at position (1) as illustrated.

• Study the relevant Installation Instruction if the passenger compartment connector socket / timer relay is to be installed at the same time as the engine block heater
• Press a cable clamp (from the kit) into place on the edge of the large hole on the underneath of the side member. See the illustration.

• Lubricate the O-ring on the front engine block heater socket connector using low temperature grease, (P/N 1161417-9).

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

• Connect the cable from the engine block heater to the front engine block heater socket cable. Firmly press the connectors together.

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

• Press the cable into the clamp
• Clamp any excess cable on the inside of the bumper on the left-hand side of the front member. Use a tie strap from the kit.

• Fill with coolant. Test drive the engine. Bleed the system. Check for leakage
• Reinstall the centre air baffle
• Reinstall the air baffles at the sides, if present
• Reinstall the engine splash guard. Tighten the screws for engine splash guard. Tighten to 25 Nm (19 lbf.ft).