Installing A Kat's Engine Block Heater On My 2004 Honda Pilot  

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Expert Reply:

The Kat's Heaters Custom Engine Block Heater - Frost Plug Style - 120V - 400 Watts - 28 mm, part # KH11419, installs in your engines frost plug. The frost plug is on the front left side of the engine, about halfway down. I have printed the instructions from the Kat's Engine Block Heater Owner's Manual. You will need a 28mm wrench, a flat head screwdriver, a punch, and pliers. The screwdriver, punch, and pliers are to aid you in the removal of the freeze plug. You will have to check a repair guide, like Chilton's, for the information about draining the coolant from your engine.

1) Refer to the most current catalog for the correct part number and position of freeze plug
heater.

2) Drain the cooling system, flush radiator and block.

3) Remove the correct freeze plug or existing heater with a punch; be careful not to nick the
wall of the freeze plug hole. Remove any burrs, sharp edges, paint or compound from the
machined surface of the hole.

4) Remove outer O ring from heater, place in hole with the element in the direction prescribed.
The element should not touch anything inside. If it does rotate the heater until the element
is free floating.

5) Lubricate O ring and machined surface of the hole with anti-freeze or silicone grease to
facilitate installation and prevent O ring damage.

6) Reinstall O ring. Back-off heater nut as far as possible, insert heating element in proper
direction, center heater in hole. And press tight. Tighten bolt to recommended torque (see
below). Do not use the screw to draw the heater into the hole. Do not over torque the bolt,
this could damage the inner O ring and cause a leak or strip the threads of the bolt.

7) Route the cord to any convenient point and tie cord down. Keep cord away from hot
surfaces and moving parts. Always have the cord attached to the heater before plugging the
cord into the wall.

8) Refill the coolant system. Check manufacturer’s instructions on mixture of anti-freeze. Do
not use more that 60% anti-freeze. Use of non distilled water could result in lime or
calcium buildup on elements and cause premature burn out of heater. Run engine until
internal thermostat opens and continue running for 20 minutes to eliminate air pockets. Test
drive the vehicle and Check for leaks.

9) Plug heater into power supply and test for proper operation. The block around the heater
should get hot. The only way to check a heater is with an Ohms meter or some other device
that will check continuity. If the heater shows continuity then check the power supply
including extension cord

expert reply by: Mark Smith

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