Engine Block Heater: Service and Repair

REMOVAL
1. Disconnect battery ground cable.
2. Drain engine cooling system.

WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE COOLING SYSTEM, USE EXTREME CARE WHEN REMOVING THE RADIATOR CAP FROM A HOT COOLING SYSTEM. WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN IT IS CERTAIN ALL THE PRESSURE HAS BEEN RELEASED, PRESS DOWN ON THE RADIATOR CAP (STILL WITH A CLOTH), TURN AND REMOVE.

3. Close radiator draincock.
4. Disconnect block heater power cable from block heater.
5. Loosen retaining screw and pry block heater from block while moving retaining screw from side to side to disengage clamp strap.
6. Remove block heater while noting the position of heating element.
7. Remove block heater power cable.

INSTALLATION
1. Clean the inside diameter of the cylinder block freeze plug hole machined surface and hole entrance. Remove any burrs at the hole entrance to avoid damage to the O-ring.
2. Apply a coating of chassis grease XG-1-C or equivalent meeting Ford specification ESA-MlC75-B to block heater O-ring and cylinder block opening.
3. Insert block heater in cylinder block.
4. Tighten screw to 1.6-1.8 Nm (15 inch lbs.).
5. Connect block heater power cable to block heater.
6. Install block heater power cable. Assure power cable is routed and secured away from rotating or hot components.
7. Refill engine cooling system with specified coolant mixture.
8. Connect battery ground cable.
9. Start engine and check for leaks.
10. Check engine coolant level as required.