Installation Procedure

Note: The following pictures are of a 1997 Elantra.






1. Remove the radiator cap.

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

2. From underneath the front of the vehicle, remove the passenger side splash guard by removing five bolts.






3. Drain the radiator of coolant by opening the drain valve located on the lower right side of the lower radiator tank.

CAUTION: Place a large pan under the area to collect the coolant draining from the radiator.






4. Unmount the power steering pump by removing the pivot bolt and the locating bolt.






5. Remove the exhaust manifold shield by removing the seven attaching bolts.






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






7. Remove the one bolt holding the exhaust system to the block.






8. Remove the three nuts/washers and disconnect the front exhaust pipe from the exhaust manifold.






9. Remove the exhaust manifold by removing the nine nuts/washers from the head.






10. Remove the tube going into the water pump by removing the one bolt. Pry back the end that plugs into the water pump by using a screwdriver to leverage the part back.

CAUTION: BEFORE THIS TUBE IS REMOVED, PLACE A LARGE PAN UNDER THE AREA TO COLLECT THE COOLANT DRAINING FROM THE BLOCK.






11. 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.
12. Clean the surface of the hole with a Scotchbrite (TM) (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.






13. Install the plug side of the block heater so that the wire connector is at the "9 o'clock" position. Tighten the locking screw clockwise to 20-25 lb.in (2.3 - 2.8 Nm).

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

14. Plug in the wiring connector.






15. Install the water pump tube at the back of the water pump. Apply a thin film of Lubriplate 105 or equivalent to the O-ring before installing the tube. Reinstall the bolt at the hose end of the tube.

Note: Always replace the O-ring when removing the pipe assembly. O-ring part no. 25462-23000.

16. Reinstall the exhaust manifold [torque the nuts to 35 lb.ft (47 Nm)]. Reinstall the heat shield, the power steering pump/bracket and the engine compartment lower plastic splash guard.






17. Route the wiring of the block heater towards the oil filter and tie wrap it to the engine block. Route the wiring along/around the wiring harness to the alternator.
18. Route the block heater wiring back up toward the lower opening of the front bumper.






19. 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.
20. Refill the radiator/reservoir with the proper mix of coolant and water. Make sure that the system is fully filled. Start the engine and check for any coolant leak.