Engine - Block Heater Installation Instructions
Group: ENGINE MECHANICALNumber: 97-20-014
Date: NOVEMBER 1997
Model: ALL SONATA 3.0L
Subject:
SONATA 3.0L BLOCK HEATER INSTALLATION INSTRUCTIONS
DESCRIPTION:
This bulletin provides a procedure for the installation of a block heater (part no. 00208-B6100) for any 3.0L Sonata model.
INSTALLATION PROCEDURES:
1. Remove the radiator cap.
CAUTION:
Make sure that the engine is cool before removing the radiator cap.
2. Remove the driver's side engine compartment lower plastic splash guard by removing seven (7) 10 mm bolts.
3. Drain the radiator of coolant by opening the drain valve located on the bottom left side of the lower radiator tank.
4. Remove the two (2) 19 mm nuts from the front exhaust manifold to the down tube exhaust pipe.
5. Loosen the two (2) 19 mm nuts holding the exhaust pipe to the rear manifold, but do not remove the nuts completely. This will allow the front down tube exhaust pipe to be lowered further to enhance the access to the core plug.
6. Remove the front exhaust manifold heat shield by removing the three (3) 12 mm bolts. Spray the bolts with penetrating oil to make the bolts easier to remove.
7. Remove the exhaust manifold by removing six (6) nuts/washers.
CAUTION:
The nuts are easily susceptible to damage. Use a six point socket and be very careful not to round the nuts.
8. From below the vehicle (on a lift), 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. Prepare for coolant drainage from the block by having a catch pan ready. Once the core plug has rotated as far as possible, use a pair of pliers to remove it.
9. 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.
10. Install the block heater so that the wire connector is at the "6 o'clock" position and plug in the wire. Tighten the 8 mm brass bolt with a torque wrench to 25 in.lb (2.8 Nm).
CAUTION:
The bolt is made of brass and will shear easily.
11. Reinstall the exhaust manifold [torque the nuts to 11-16 lb-ft (15-22 Nm)]. Reinstall the heat shield and the engine compartment lower plastic splash guard.
12. Route the block heater wiring towards the passenger side and down along the lower radiator tube towards the front bumper cover. Be sure to leave approximately 3 inches of slack in the wiring between the engine and the body to allow for engine rocking/movement. Secure the block heater wiring by tie-wrapping to existing vehicle wiring harnesses.
13. Wrap the plug end of the block heater wiring to the cross bar in the lower bumper opening 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.
14. 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.