B5.9G, B5.9LPG – Troubleshooting and Repair Manual – 008-011   Coolant Heater

CAUTION  Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations.

Cylinder Block Water Heater

• Drain at least 19 liters [5 gal] of coolant. Refer to Procedure
  008-018.

Disconnect the block heater electrical cord.

10 mm

Loosen the block heater retaining nut.

Remove the block heater from the block.

Clean the core plug hole thoroughly. Make sure there are no burrs or sharp edges that can cut the o-ring.

Lubricate the new heater o-ring with clean lubricating engine oil.

The locking channel (T-bar) should be threaded out to the end of the bolt. If so equipped, do not remove the retaining wire used to position the channel (T-bar).

Hook the element and one leg of the channel (T-bar) into the hole as illustrated.

Hook the other leg of the channel in the hole, and push the heater into the hole as far as possible by hand.

CAUTION  Do not pull the heater into location with the locking bolt as the channel (T-Bar) can bend or cause the threads to strip.

Plastic Hammer

If necessary, use a plastic hammer to tap the heater in until the shoulder contacts the block.

10 mm Socket, Inch lb. Torque Wrench

NOTE: Do not overtighten.

Insert the power cord into the socket being careful to align the pins with the sockets of the power cord. Tighten the retaining nut by hand.

Do not apply power until the cooling system is filled, and has run long enough for the thermostat to open and allow the air to escape.