Engine block heater diesel (D5252T MSA 15.8)

• Remove the overrider moulding from the bumper. Pry up the moulding at one corner using a plastic weatherstrip tool. Then pull off the entire moulding.

• Cut a hole in the overrider moulding following the marking (1) on the reverse of the moulding. Leave a safety margin when cutting. Use a utility knife or similar. Finely adjust the size of the hole using a file.

Примечание: When cutting along the upper horizontal line, angle the knife towards the upper edge of the moulding. Guide the knife along the moulding. This is so that the cut is not positioned in the centre of the curvature of the moulding.

• Install the protective cover (1) for the front engine block heater socket in the overrider moulding
• Mark out the hole in the bumper cover (2) using a 29 mm (1 1/8") diameter hole saw and its central drill bit
• Remove the protective cover. Drill out the hole using a 29 mm (1 1/8") diameter hole saw
• Remove any swarf
• Reinstall the protective cover.

• 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.

• Slacken off the screws (1). Remove the air baffle (2)
• Remove the screws (3). Remove the splash guard (4).

• Route the cable for the front engine block heater socket through the protective cover (1) and the bumper cover (2)
• Install the plastic nut (3) from the kit on the front engine block heater socket. Tighten the plastic nut. The cover must be horizontal and is opened forwards.

Ground terminal for the cable under the 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 to the side member, not to the sub-frame.

• 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 located in the middle of the cylinder block. Use 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
• Secure the mounting as illustrated. Tighten the mounting. Tighten to 50 Nm (37 lbf. ft.)
• Secure the cable at the pipe on the right-hand side at the rear edge of the sub-frame. Use a tie strap from the kit.

Illustration A

Applies to left-hand drive cars when only installing the engine block heater

• Remove the existing nut from the steering gear
• Install the mounting bracket for the junction switch and cables
• Install the new lock nut supplied. Tighten to 48 Nm (36 lbf. ft.)
• Secure the first tie strap on the servo coolant pipe. If there is no servo coolant pipe; drill out the first hole to a diameter of 6.5 mm (1/4"). Secure the tie strap as normal.

Illustration B

Applies to left-hand drive cars when installing the passenger compartment connector socket and the engine block heater at the same time

• Install the Y connector on the bracket. Use the screw and nut from the kit
• Lubricate the O-rings. Use low temperature grease (P/ N 1161427)
• Connect the wiring from the front engine block heater socket (1), passenger compartment socket (3) and engine block heater (2) to the Y connector
• Tighten the Y connector and the bracket on the steering gear. Tighten to 48 Nm (36 lbf. ft).

• Route the cable from the bumper above the front edge of the sub-frame and backwards to the cable from the engine block heater
• Secure the cable using tie straps in the existing holes
• Connect the cable from the bumper to the cable from the engine block heater. Alternatively connect the cable from the bumper to the Y connector.

Примечание: Do not clamp to the drive shaft. Ensure that the cable does not rub against any sharp edges. The wiring must also be kept away from the turbocharger (TC) and exhaust pipe to prevent damage from radiant heat.

• Install the locking sleeves over all the connectors and cable splices on the wiring. Ensure that they are correctly installed.

• Reinstall the air baffles and the splash guard. See points 4 and 5
• Tighten the screws for the splash guard. Tighten to 25 Nm (19 lbf. ft)
• Clamp the engine heater cable in the mounting on the left-hand side of the air baffle.

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