Engine - Block Heater Installation

83chrysler8

Models


1983-1984 Power Ram 50 Pick-Up Trucks Equipped With 2.3L Turbo Diesel


Subject


Engine Block Heater Installation


Index


ENGINE

Date October 17, 1983


No.


09-11-83

P-3988-C
An engine block heater is standard equipment in the 2.3L turbo diesel engine. The heater improves the startability of the engine in cold weather. The procedure for replacing the engine block heater is described below:



REPLACEMENT PROCEDURE

Removal Procedure

1. Drain engine coolant.

2. Disconnect the power cord (harness) from the engine block heater.

FIGURE 1:

3. Loosen the retainer screw and remove the engine block heater from the cylinder block expansion plug hole (Figure 1)..

FIGURE 2:

Inspection

1. Measure resistance of the engine block heater with a circuit tester (Figure 2). Normally, a measured resistance is 100 Ohms or more.

2. Check the harness for breaks.

FIGURE 3:

Installation Procedure

1. Loosen the retainer screw as far as possible. Lubricate both O-rings with petroleum jelly (Figure 3).

FIGURE 4:

2. Install the heater into the expansion plug hole, being careful not to nick or cut the O-rings. Position it so the connector pins are located toward the front of the engine as shown in Figure 4. Tighten the screw only enough to lightly compress the O-ring.

CAUTION: OVERTIGHTENING OF THE RETAINER SCREW MAY STRIP THE THREAD SCREWS AND CAUSE A COOLANT LEAK.
3. Connect the power cord (harness) to the engine block heater.

4. Fill cooling system.

5. Start the engine and warm to operating temperature. Check for leaks.

CORD REMOVAL & INSTALLATION INSTRUCTIONS

Removal

1. Disconnect battery and remove it from its tray.

2. Remove power cord from plastic clips.

FIGURE 5:

Installation

1. Using existing clip #1 (Figure 5), clip the heater harness to the fuel line and glow plug harness.

2. Use existing clips #2, 3 and 4 (Figure 5) to clip the heater harness to the engine compartment wire harness.

3. Fasten the heater harness to the engine compartment wiring harness at points #5 and 6 (Figure 5) with Cable Bands PN MB084081. Be sure to place the cable bands near the front and rear of the battery as shown.

4. Clip the heater harness to the hood release cable at point #7 (Figure 5) using the existing clip.

FIGURE 5:

FIGURE 6:

5. Clip the heater cable into cable clip #8 as shown in Figure 5. Allow about 2 inches of heater harness to hang free as shown in Figure 6.

6. Reinstall the battery, taking care not to pinch the header harness. Torque the hold-down bolts to 3 N-m (20 in.lbs.).

FIGURE 7:

REMOVAL PROCEDURE FOR EXPANSION PLUG OF SERVICE CYLINDER BLOCK

The service cylinder block has its expansion plug press fitted. When installing the engine block heater, remove the expansion plug by the following procedure:

1. Locate the expansion plug at the left rear side of the engine cylinder block (Figure 7).

FIGURE 8:

FIGURE 9:

2. To remove the expansion plug, position a blunt punch as shown in Figure 8 and drive the expansion plug inward until it is free. Then, use pliers to remove it from the cylinder block as shown in Figure 9. Clean and deburr the expansion plug hole to prevent damage to the block heater O-ring.

CAUTION: IF THE PLUG ACCIDENTLY FALLS INTO THE WATER JACKET, REMOVE IT, OR OVERHEATING MAY RESULT.

FIGURE 10:

3. Use a blunt punch to bend the chaplet (metal), which is located in the water jacket, away from the expansion plug hole. This will provide clearance for the heating element of the block heater (Figure 10).
POLICY: Information only