Installation Procedures

Note: For reference purposes, pictures are of a 1998 Accent. Earlier California, Federal and Canadian vehicles may vary in components but the basic procedure is the same.






1. Remove the radiator cap and raise the vehicle on a hoist.

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






2. Remove the passenger side engine compartment lower plastic splashguard by removing the five (5) bolts (M6) and one plastic push screw.






3. Drain the coolant from the radiator into a large container by opening the drain valve, located on the right side of the lower radiator tank.






4. Remove the two (M11) nuts from from the bottom of the catalytic converter.

Note: During installation (M11: torque to 36 lb.ft, 48.8 Nm)

TIP: Squirt some Hyundai Rust Penetrant (P/N 00232-12150) or equivalent on the nuts to ease the removal process and lessen the possibility of damaging the fastener.






5. Lower the vehicle. Remove the plastic air intake plenum by removing two bolts (M6).






6. Disconnect the upper radiator hose at the radiator end and move the hose out of the way.






7. Disconnect the wiring for the passenger side radiator fan unit. Remove the passenger side fan unit by removing the two upper bolts (M6) and loosening (do not remove all the way) the two lower bolts (M6).






8. Remove the three (M8) bolts holding the exhaust manifold heat shield in place.

Note: During installation (M8: torque to 13 lb.ft 17.6 Nm)

CAUTION: Do not attempt to remove the heat shield. The bolts are removed to gain access to the exhaust manifold nuts.

TIP: Squirt some Hyundai Rust Penetrant (P/N 00232-12150) or equivalent on the bolts to ease the removal process and lessen the possibility of damaging the fastener.






9. Disconnect the upper oxygen sensor wiring connector.






10. Remove the nine (M6) nuts holding the exhaust manifold to the cylinder head.

Note: During installation (M6: torque to 13 lb.ft, 17.6 Nm)

TIP: Squirt some Hyundai Rust Penetrant (PIN 00232-12150) or equivalent on the nuts to ease the removal process and lessen the possibility of damaging the fastener.






11. Remove the exhaust manifold, catalytic converter and the heat shield as a single unit. Then remove the spark plug wire shield.






12. Place a coolant drain pan under the vehicle to prepare to catch the coolant from the engine block. Firmly place a clean rag into the exhaust pipe to keep coolant from entering the exhaust system.






13. Remove the second from the left core plug from the engine block by using a hammer and a flat tipped punch at the "3 o'clock" position of the outer ring of the core plug. By hammering the punch at the outer flange only, the 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 it.
14. Clean the surface of the core hole with a Scotchbrite (TM) (or equivalent) pad to make sure that there is no debris or metal burrs. An irregularity of the surface may damage the O-ring on the block heater during the installation process.






15. Install the block heater so that the wire connector is at the "9 o'clock" position and tighten the brass bolt with a torque wrench to 2.1 lb.ft (equal to 25 lb.in, 2.8 Nm).

CAUTION: The bolt is made of brass and will shear easily.

16. Plug in the wire and route the wire so that it will not come into contact with the exhaust manifold heat shield.






17. Use the supplied tie wraps to secure the block heater wire along the alternator wire harness and out to the front bumper's lower opening. Wrap the plug end of the block heater wiring around the bumper's lower opening horizontal bar and double tie wrap in place. Make 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.
18. Reassemble all removed components in reverse order. Torque all nuts & bolts as specified in these instructions. Be sure to reconnect all disconnected wire connectors.
19. Refill the radiator/reservoir with the proper mix of coolant & water. Make sure that the system is fully filled. Start the engine and check for any coolant leaks.