Installing the front engine block heater socket

Installing the front engine block heater socket

• 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.

  
  

  Note! 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 aligns. Adjust the hole using a knife or file as necessary.

• Smooth off the hole edges. Remove any swarf.

• Remove the seven screws holding the engine splash guard and remove the guard.

• Remove the left and right-hand front wheels.

• Remove the five screws holding the bumper shell in the fender liner on the left and right-hand sides.

• Remove the nut holding the left-hand fender liner to the front member.

• Bend the front edge of the left-hand fender 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 covers for the nozzles for the headlamp washers 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 washer nozzles.

• Detach the ends of the bumper shell on the left and right-hand sides. Grasp the end of the bumper shell inside the fender liner. Carefully pull the end of the bumper shell 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 hole cut 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.

Cable routing

Cable routing

• 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 edge. Ensure that the air baffle is correctly positioned in its mounting.

• Reconnect the connectors for the fog lamps and parking assistance if applicable.

• Press the ends of the bumper shell into place on the body.

• Route the front intake cable from the front edge of the cover for the control module, along the bottom edge of the front member and over the drive shaft. Insert the cable into the engine compartment a little.

• Install steel clips as illustrated.

• Install the cable harness and secure it with cable tie in the subframe. Insert the cable into the engine compartment a little.

• Clamp with the edge clips at the battery shelf.

• 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 Ø4 mm (5/32 ”) hole for the ground lead, on the outside of the left-hand front member, approximately as illustrated.

• Treat the edges of the holes using a rust-proofing agent.

• Secure the ground lead in the drilled hole. Use the screw and toothed washer from the kit.

• Affix the excess length of ground lead at the existing clips.

• Install three clips from the kit on the front edge of the panel above the windscreen wiper motor.

• Guide the cable up to the top of the engine compartment to the position illustrated.

Illustration A

• Press the front intake cable into the clips. Guide down the cable at point (1) and route down through the engine compartment (behind the AC pipes) down to the strut in the right link arm mounting.

Illustration B

• Clamp the cable at the existing cable harness.

  
  

  Note! The cable must not be clamped directly to AC, fuel or brake pipes.

  
  

• 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.

  
  

  Note! Do not get any grease on the surfaces of the connector.

  
  

Applies to cars where the engine block heater and passenger compartment connector socket are installed 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 installed 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, toothed washer and nut from the kit. The bracket must be parallel to the length of the junction connector.

Position (1) cable for the engine block heater

Position (2) cable for the passenger compartment connector

Position (3) cable from the front engine block heater socket.

Applies to cars where the engine block heater and timer relay are installed at the same time

• Tighten the timer relay at the bracket (purchased separately) in the position illustrated. Use the screw, toothed 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.

Position (2) cable for the engine block heater

Position (3) cable from the front engine block heater socket.

Applies to cars where the passenger compartment connector socket and the timer relay are installed at the same time

• Tighten the timer relay at the bracket (purchased separately) in the position illustrated. Use the screw, toothed 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.

Position (1) cable for the passenger compartment socket

Position (2) cable for the engine block heater

Position (3) cable from the front engine block heater socket.

• Connect the short cable from the kit to the engine block heater, to the routed cable (1) from the front socket. (When fitting junction connector/timer relay at the same time, the cable from the front socket is connected to the single outlet on the junction connector/timer relay instead. Refer to the installation instructions for passenger compartment socket/timer relay).

• Firmly press the cable junction together.

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

• Take a double tie strap from the kit. Install the double tie strap around the stay and the cable splice. Ensure that the splice is secured in the centre of the strut. Tighten the double clamp properly.

Installing the engine block heater

Installing the engine block heater

• Remove the cover on the radiator expansion tank.

• Unscrew the drain nipple in the radiator pipe above the oil cooler in front of the right drive shaft. Drain the coolant.

• Remove the left of the two coolant hoses from the cooling pipe and the oil cooler. Discard it, it will be not used again. New hose in the kit.

Illustration A

Illustration B

• Take the heater, rubber covered clamp, bracket and self tapping screws from the kit and assemble as illustrated. The short pipe for the heater (1) must be perpendicular to the long side of the bracket, see image B. Ensure that the short pipe for the heater is centred in the cut out (2) in the bracket where the heater is secured.

• Do not tighten the rubber covered clamp fully yet.

• Take two short heater hoses and four hose clamps from the kit.

• Install the two hoses to the engine block heater with the shortest hose on top.

• Tighten the hoses to the engine block heater using the hose clamps located as illustrated.

• Fit the two remaining hose clamps onto the heater's hoses as illustrated.

• Move the heater up into position behind the oil cooler and press the heater hoses onto the outlets in the oil cooler and the pipe for the oil cooler.

• Take the three self-tapping screws and the three spacer sleeves from the kit and tighten the bracket with the heater into the rear edge of the oil sump.

  
  

  Note! The screws are self-tapping so it may be slow inserting them. Make sure that the screws are centred straight into the holes, so that the screw heads are flat against the bracket.

  
  

• Tighten the two loose hose clamps and adjust the position of the engine block heater connector so that it does not make contact with the servo hose or charge air hose.

• Tighten the engine block heater firmly to the bracket.

• Connect the short electrical cable (1) that was routed earlier, to the engine block heater. Press it firmly into the engine block heater connection.

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

• The cable between the engine block heater and the cable splice on the stay to the subframe has a certain excess and must be clamped together: Take cable ties from the kit and clamp up the excess cable.

• Reinstall the left-hand fender liner. Tighten the fender liner to the left-hand side member.

• Tighten the two fender liners to the bumper shell on the right and left-hand sides.

• Fill with coolant, run the engine to operating temperature, bleed the cooling system and check that there are no leaks.

• Reinstall the engine splash guard.

• Remount the front wheels and tighten the lug bolts to 90 Nm (66 lbf.ft.).