Installation Procedures

1. Remove the radiator cap.





CAUTION:
Make sure that the engine is cool before removing the radiator cap.

2. Drain the radiator of coolant by opening the drain valve located on the bottom left side of the lower radiator tank.

3. Raise the vehicle and remove the three nuts at the bottom of the exhaust manifold.

4. Remove the two bolts holding the exhaust system to the engine block.

5. Disconnect the two oxygen sensor connectors.

From electrical trouble shooting manual (ETM):

California: C07-1 & C43

Federal: C07 & M38

6. Detach the lower oxygen sensor connectors from their bracket by using a curved awl to push in the retaining clip.

7. Remove the air intake plastic resonance box by removing two bolts and loosening one hose clamp.

8. Bend back the wire tab on the heat shield. Remove the exhaust manifold heat shield by removing the three retaining bolts.

9. Un-mount the power steering pump by removing the pivot bolt & the locating bolts. Remove the belt from the power steering pump pulley.

10. Move the power steering pump out of the way (as shown in photo).

11. Remove the power steering pump bracket by removing three mounting bolts.

12. Remove the engine hook bracket by removing two nuts from the exhaust manifold and one bolt.

13. Remove the exhaust manifold by removing the seven nuts/ washers from the head.

14. Remove the tube going into the water pump by removing one bolt on the front side of the block, one bolt at the top of the transaxle and disconnect the large lower radiator hose as well as the two smaller hoses. Pull back the end plugged into the water pump. Be sure to replace the O-ring from the tube.

CAUTION:
Before this tube is removed, place a large pan under the area to collect the coolant draining from the block.

15. Clean the bore at the water pump with a Scotchbrite or equivalent pad.

16. Remove the right front core plug from the block by using a flat tipped punch at the "9 o'clock" position of the outer ring of the core plug. By hammering the punch at the outer flange only, the core plug can be made to rotate in the hole, thus facilitating the removal process. Once the core plug has rotated as far as possible, use a pair of pliers to remove the core plug.

CAUTION:
Make sure that the punch is located on the outer flange of the core plug, not on the inside.

17. Clean the surface of the core hole with a Scotchbrite or equivalent pad to make sure that there are no debris or burrs. An irregularity of the surface may damage the O-ring on the block heater during the installation process. Locate the plug side of the block heater at the "6 o'clock" position for best clearance to the coolant tube.

18. Tighten the locking screw clockwise to 20-25 in.lb (2.3 - 2.8 Nm).

CAUTION:
Do not overtighten the screw as this may strip the threads or stress the lock.

19. Plug in the wiring connector.

20. Clamp the coolant tube (previously removed) in a bench vise using either tube clamping jaws or soft jaws so as to not damage the tube. Using a ball peen hammer, indent the tubing in the area of interference to the block heater. Indent the area approximately 1.5 inches long by 0.4 inch deep.

21. Install the water pump tube assembly at the back of the water pump. Apply a light film of Lubriplate 105 or equivalent to the O-ring before installing the tube. Reinstall the bolt at the front of the block, top of the transaxle and all hoses and clamps.

Note:
Always replace the O-ring when removing the pipe assembly. O-ring part no.25462-21010.

22. Reinstall the exhaust manifold [torque the nuts to 20 lb-ft (27.1 Nm)]. Reinstall the heat shield and the power steering pump/bracket.

23. Route the wiring of the block heater towards the lower right area of the radiator. Tie wrap to the engine mount bracket area, making sure that there is enough slack in the wiring to compensate for engine rocking. Route the wiring near the lower radiator hose and wire tie securely.

24. Route the block heater wiring back up toward the lower opening of the front bumper and wire tie to the lower radiator support bracket.

25. Tie-wrap the rest of the block heater wiring to the cross bars on the lower opening of the front bumper, making sure that the plug will be easily accessible yet not so loose as to cause damage to the front bumper when the vehicle is driven.

26. Refill the radiator/reservoir with the proper mix of coolant & water. Make sure that the system is fully filled. Check for any coolant leaks.