Electric Engine Block Heater, 115V
Electric engine block heater 115V, B8444S
Electric engine block heater, 115V
Preparations
- Detach the left-hand headlamp by pulling up the two locking pins and then carefully pulling away the headlamp forwards.
- Carefully prize up the catch on the connector for the headlamp using a screwdriver.
- Pull the catch up completely, detach the connector and place the headlamp to one side.
- Remove the screw in the upper engine mounting. Remove the four screws holding the strut between the spring strut turrets and lift out the strut.
- Remove the rear engine cover behind the intake manifold by pulling it away backwards. It is fitted with four rubber mountings.
Installing the front engine block heater socket
Applies to cars from model year 2007-
- Clean the surface where the front engine block heater socket will be secured.
- Drill a hole for the guide to the front engine block heater socket's mounting plate.
- File down the edges of the holes.
- Drill a hole for the tie strap for the front engine block heater socket's cable.
- File down the edges of the holes.
- Cut away the three pins on the front engine block heater socket's mounting plate.
- Drill a -5 mm (3/16 ") diameter hole in the mounting plate.
- File down the edges of the holes.
Applies to all models
- Assemble the front engine block heater socket using the parts from the kit, in accordance with illustrations A, B, C and D.
Illustration A
Illustration B
Illustration C
Illustration D
Applies to cars from model year 2007-
- Install the front engine block heater socket with the guide pin in the large hole.
- Route the cable in so that it runs down on the inside of the left-hand bracket for the skid plate.
- Align the front engine block heater socket so that the long sides of the mounting plate are parallel with the edges of the surface into which the mounting plate shall be screwed.
- Mark out for drilling the hole for the screw for the mounting plate.
- Drill a -5 mm (3/16 ") diameter hole for the screw for securing the front engine block heater socket's mounting plate.
- Install the front engine block heater socket with a screw and nut in the drilled hole and tighten.
- Secure the tie strap in the hole around the front engine block heater socket's cable.
- Fold in the connector so that the cable adopts the correct length in the tie strap before it is tightened.
- Tighten the tie strap.
- Clamp the cable in at the pipe for the air conditioning using a double tie strap.
- Route the cable up on the inside of the side member and under the plate underneath the headlamp.
Applies to cars up to and including model year -2006
- Guide the front socket's cable in through the centre hole, next furthest to the left in the grille.
- Take a screw, washer and attaching plate from the kit and install the front socket. Push it as far as possible to the left and tighten it.
- Route the cable to the left, in through the rubber seal on the left-hand side of the radiator and under the plate on the underside of the headlamp.
Installing the heater, applies to all model years
- Route the cable back along the left-hand side of the air cleaner and between the air cleaner and fuse holder. Continue to route it backwards, under the ABS system and up between the cable duct and brake fluid reservoir.
- Check that the cable does not chafe against sharp edges or moving parts in the engine compartment.
- Clamp with tie straps from the kit.
Note! Do not clamp the cable against brake pipes, fuel lines or air conditioning (A/C) pipes.
- Open the cover for the radiator expansion tank.
- Take two clips from the kit and install them in the edge of the plate at the front edge of the panel above the windscreen wiper arms.
- Remove the six screws and the engine splash guard.
- Remove the four nuts in the joints to the manifold and the two in the joint in the front edge of the front silencer.
- Detach the pipe above the exhaust manifold from the clips in the brackets to the exhaust manifold's front mounting.
- Remove the four screws in the brackets
- Detach the heat deflector plate's two clips from the brackets.
- Remove the exhaust pipe and catalytic converters.
Note! Take care with the twisted parts of the exhaust manifold.
- Detach the engine block drain nipple under the left-hand side of the rear manifold and drain the coolant.
- Tighten the nipple when the coolant is drained.
Illustration A
- Remove the plug in the engine block under the left-hand side of the rear manifold.
Illustration B
- Use hexagon socket P/N 9512965, socket extension 120 mm (4 3/4") with spherical end, socket extension 500 mm (19 11/16 ") with spherical end and handle.
Illustration C
- Apply a piece of butyl tape on the hexagon socket so that the plug does not fall away when it is unscrewed.
Note! Removing the plug requires significant force.
- Take the heater from the kit.
Hint: Try to rotate the connector in the heater before installation to reduce any friction.
- Brush thread sealant P/N 1161056 on the threads.
- Install the heater in the engine block and manually screw it on as far as possible. It may be difficult to make the threads engage in the hole as the connector rotates stiffly in the threaded part of the heater.
Illustration A
- Take tool P/N 9814012, a 1/2"- 3/8" adapter, the two socket extensions and a 1/2" ratchet handle.
Illustration B
- Tighten the heater firmly to the engine block.
- Press the cable to the engine block heater into the clips.
- Take the radiation shield from the kit and pull it on the end of the cable.
- Guide the cable down to the location where the engine block heater was installed.
- Grease in the O-ring on the connector for the heater's cable using low temperature grease (P/N 1161417-9).
Note! Do not get any grease on the surfaces of the connector.
- Firmly press in the connector to the engine block heater.
- Press a locking sleeve (from the kit) over the cable splice.
- Pull the radiation shield down so that it fully covers the connector.
- Take the grey tie strap from the kit and tighten the radiation shield to the cable at the top edge.
- Connect and reinstall the left-hand headlamp.
- Reinstall the engine's rear protective cover.
- Reinstall the strut between the spring strut turrets.
Torque tighten the four M10 screws to 50 Nm (37 lbf.ft.) and the M12 screw to 80 Nm (59 lbf.ft.).
- Make sure that all sealing surfaces are thoroughly cleaned and reinstall the exhaust manifold with new gaskets and clamp nuts from the kit. Torque tighten to 25 Nm (18.5 lbf.ft.).
- Clamp the pipe above the bracket into its clips.
- Align the clips for the heat deflector plate's mounting in the bracket for the exhaust manifold's mounting.
- Tighten the bracket for the exhaust manifold's mounting to 25 Nm (18.5 lbf.ft.).
- Fill with coolant, drive to normal operating temperature and bleed the system. Check that there are no leaks.
- Top up with coolant as required.
- Reinstall the engine splash guard and torque tighten the screws to 25 Nm (18.5 lbf.ft.).