Block heater installation - block heater won’t seat

[SkylabTech86IDI]

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hi all, I’m installing a new block heater that was tested to work to replace the non-working block heater element.

I’m having a problem getting the block heater plug to seat in the cavity. It’s like the O-ring doesn’t want to seat, and only up to 50% of the plug seems to be seated at a time.

Are you supposed to push the block heater plug flush into the cavity before tightening it, or are you suppose to line the block heater plug up as best you can and use the hex nut bolt to pull the plug into the block?

I’ve broken 3 hex nut bolt now trying to seat the block heater back into place.

 

[SkylabTech86IDI]

I see there are instructions to Point element at 11 o'clock position but in the picture that I sent, that heating element is close to in the 11 o clock position.

I’m going to the store to grab new hardware and try again tomorrow

 

[IDIBRONCO]

Yes close to the 11 o'clock position is correct. I don't think that you can pull the heater in far enough with the bolt to get it to seat. I tighten up the bolt enough so that it holds pressure on the heater and then tap it in the rest of the way with a rubber mallet or a dead blow hammer. I also like to put a thin layer of RTV on the block heater o-ring before I install it. There's two reasons for that. One, it will help lubricate the o-ring and let it slide into place easier. Two, that sealing area can be pretty rough sometimes and(hopefully) it will help to seal up small imperfections.

 

[SkylabTech86IDI]

Got it, thank you

Here’s a 8 second video of the truck after the block heater install and oil cooler rebuild

 

[IDIBRONCO]

Sometimes they can be stubborn.

 

[SkylabTech86IDI]

Sometimes they can be stubborn.

Stubborn they can be, indeed.

So an update: I put 3-ish more miles of easy driving on the truck after I installed the block heater replacement. In that link is a 2 minute example of a drive.

After vetting the running condition, I was going to use the truck to pick up furniture and some engine parts and before setting off I gave the truck a good rev right in front of the house. Wouldn’t you know it, the block heater blew out

Frustrating but got to stick with it