Engine block heater diesel (3)

• Remove the air baffle.

• Remove the splash guard.

• Mark the hole in the centre of the left-hand side of the bumper, vertically down from the rear edge of the indicator lamp lens
• Secured the supplied drill template to the bumper
• First drill a hole using a 4 mm (5/32") diameter drill bit then drill out using a 29 mm (1 9/64") hole saw
• Adjust the guide hole for the expander nut using a round file.

• Install the expander nut (1) in the hole
• Thread the cable supplied (2), including the ground lead, through the hole
• Assemble the supplied connection cable (3) with the cable at the expander nut. Screw clockwise so that the expander nut engages
• Remove the connection cable.

Примечание: Ensure that the drainage hole for the front engine block heater socket is open.

• Mark out the hole under the member for the ground terminal for the ground lead
• Drill the hole using a 4 mm (5/32") diameter drill bit
• Rust-proof the hole. Secure the ground lead using a screw and toothed washer from the kit.

• Install the clips (1) on the engine mounting frame
• Position the cable from the heater in the clips (1).

• Grease the O-ring using low temperature grease, (P/N 1161427).

Примечание: Ensure that no grease gets on to the contact section.

• Remove the existing nut on the steering gear
• Install the bracket for securing the wiring. Use the nut supplied. Tighten to 48 Nm (36 lbf. ft.)
• Connect the cable from the bumper to the heater cable. Check that the connector is properly joined (see illustration B)
• Install the safety lock over the connection
• Press a tie strap (from the kit) on to the bracket on the steering gear. Clamp around the cable
• Check that the cable is not rubbing against any other components.

Примечание: The cable must not be secured to the fuel lines, air conditioning (A/C) pipes or brake pipes.

• Install a clip (1) on the bearing bracket for the drive shaft (2). Secure the clip by hand first, then use a pipe wrench or similar
• Install the cable from the heater in the clip.

• Grease the O-ring, see point 7
• Connect the cable to the engine block heater. Press the connectors together so that there is no play between the connector sockets. See illustration 8B
• Install the safety lock over the connection.

• Open the cover for the radiator expansion tank
• Position a container under the engine. Open the coolant drain cock
• Drain the coolant. Close the drain cock.

• Pull out the core plug from the middle of the cylinder block using an extractor.

• Thread the O-ring on to the heater
• Lubricate the O-ring using low temperature grease, (P/N 1161427)
• Install the heater on the block
• Install the mounting bracket as illustrated. Tighten to 50 Nm (37 lbf. ft.)
• Clamp the cable.

Примечание: Do not clamp the cable to the drive shaft.

• Route the cable through the hole at the left-hand mounting for the air baffle
• Reinstall the air baffle
• Reinstall the splash guard.

• Fill with coolant. Run the engine to operating temperature.