GEN III Engine Block Heater Installation

[hobbit]

I helped Wayne research doing block heaters on the Gen III back
at Hybridfest, and we got a bunch of pictures of our exploratory
process. I've written it up, available here, and referencing
my gen-2 instructions and that other long-running "want to install
a block heater yourself?" thread.
.
I deliberately did *not* include anything about routing the power
cord for the heater. That's something that DIYers can figure out
their own preferred path on! At the end it shows what can happen
when those cheezy molded plugs get a little too much abuse.
.
_H*

[jayman]

Originally Posted by hobbit

At the end it shows what can happen
when those cheezy molded plugs get a little too much abuse.
.

H

Good writeup as usual

Those molded plugs will fail due to all the flexing they experience. Not only from plugging in and unplugging, but also from flapping around in the breeze driving down the highway

I've never gotten more than 3 winters out of a heater plug before it failed. Don't just chop off right at the plug, as I can almost guarantee the stranded wire inside has failed as well, due to the repeated flexing. Chop at least 2 inches further up the plug

Like you, I much prefer "real" plugs. I like these

http://www.passandseymour.com/pdf/H07.pdf

They have the plastic inserts to hold small, flat cordsets. For making "real" extension cords, the inserts can be thrown away. Actually, for heavy duty cordsets, I prefer this plug

http://www.passandseymour.com/pdf/H05.pdf

This way, the cord goes straight down and there is little strain on the cord

[spiderman]

Just curious, what is the lifespan on these heaters?
Peter

[jayman]

Most blockheaters, I've managed to get 4-6 years before they burned out. That is, not a dead short, but just open. Keep in mind I live in a pretty harsh winter climate, it can get to -40, so folks tend to leave their block heaters plugged in 24x7 once cold weather hits

[Dark_matter_doesn't]

Originally Posted by hobbit

I helped Wayne research doing block heaters on the Gen III back
at Hybridfest, and we got a bunch of pictures of our exploratory
process. I've written it up, available here, and referencing
my gen-2 instructions and that other long-running "want to install
a block heater yourself?" thread.
.
_H*

Thanks much for posting the instructions with great photos. You describe going in from the top to do the described installation but imply that it can be done from underneath. Can the install be done from underneath except for the 110 VAC cord routing?

[FireEngineer]

Originally Posted by Dark_matter_doesn't

Thanks much for posting the instructions with great photos. You describe going in from the top to do the described installation but imply that it can be done from underneath. Can the install be done from underneath except for the 110 VAC cord routing?

Yes, you can install the heater from underneath and not take apart the cowl, my prefered way. You still need to unbolt the wire retainer from the top, but then open the oil change flap underneath and you can easily reach the cylinder to insert the heater.

Wayne

[FireEngineer]

OK everyone in the Chicagoland area and anyone else who wants to make the drive, here is the Chicago event Chicagoland engine block heater install event.

Wayne