Coolant Heater Lower Grill Outlet

[fitzski]

I've been wanting an easier, cleaner way of plugging and unplugging the Zerostart coolant heater since the first day I had to deal with a frozen up plug or had to fish it back through the grill.

I figured some kind of outlet should be readily available, although I wasn't able to find much choice - I ended up with a Marinco "On-board Charger Inlet" (part #150BBI; Marinco's specifications). Marinco products are readily available through just about any marine supply store. In Ottawa, I got mine from The Chandlery for less than CDN$20 (I also picked up a Pela oil extractor).


I did not want to cut the male plug off the Zerostart heater, so instead I cut the female end off an old exterior grade single outlet extension cord (~8" in length) and wired that into the Marinco outlet. This lets me plug/unplug the heater easily for any reason (removing the grill, removing the bumper, removing the heater, etc.). Not a necessary step, but one I'm glad I did.


Heater cord plugged into Marinco extension outlet. I also put some dielectric grease on each terminal as extra protection.


My initial thought was to put the outlet on the black part of the lower bumper valance. I was skeptical of this mostly because I wasn't confident in getting a solid fit because of the curves - there aren't too many completely flat areas of the size required, as the outer flange on the Marinco outlet is fairly large. I decided I would just put it in the grill - if it didn't work out, no biggie, finding a replacement grill would be easy enough.

I marked out the location of the outlet through the "solid" part of the grill, to make sure it would have maximum support when pushing in and pulling out the extension cord. I used a dremel and knife to do the cutting - a bit awkward and not the prettiest behind the scenes, but it worked. Be mindful of the retaining tabs on the grill; they can be easily bent while working on cutting the hole. A hole saw would work best, but I didn't have one of the appropriate size. This is important - the installation instructions call for a hole of 1 7/8" so that the threads will pass through easily. I would recommend <font color="red">1 3/4"</font> - just a bit smaller - so that you can thread the outlet into the grill and get a really good bite into the plastic. It is basically a friction fit, because you cannot use the threaded retaining ring to support the outlet - the grill is too deep.


I was going to silicone/goop the outlet in place, but I didn't need to - it is solid and won't budge. The outlet is barely noticeable in the grill. Time will tell how it handles the abuses of winter, but I think it will work well.


Extension cord plugged into outlet:



(Edit: Marinco links updated, Oct 2007)

[ARBY]

This should go in the 'How-To' thread. Very nice.

[mtltdi]

nice work. I have Hella DRL's so I'd have to try something different, the center grille is pretty flimsy so that's not a good idea, I'll have to go out and take a look.

I go to Ottawa often, could you tell me where this store is located?

Thanks

[unixb0y]

It would be neat to mount it behind the VW emblem on the grill and sticking the emblem on the cover.

I doubt there would be enough room. You'd probably have the dremel the crap out of the grill too.

[fitzski]

The Chandlery is near the Richmond/Carling intersection. Exit the 417 at Pinecrest (north), bear right on Richmond, then left on Poulin (the light after you cross Carling). It's in the little mall immediately at the bottom of the hill. I'd call ahead and have it set aside, just in case. [Google Map]

Putting the outlet in the lower valance is definitely a viable option, but it's that extra bit more awkward to reach, a bit more vulnerable to road hazards, and the risk is a bit greater (albeit still minimal) if something goes wrong during the install.

You could put it ABOVE the grill, or on the side in front of the wheel, but to me that was an aesthetic issue, because you'd be cutting into the body coloured bumper. As you know, there's plenty of space behind the left front fender. Cut a 2-1/2" piece of paper and find a spot! The cord on the heater is quite long, too, so you aren't necessarily restricted to that corner of the car.

Ooooh yeah! Something behind the grill logo would be very cool!

[boardom]

That's a pretty sweet setup fitzski.. I've been thinking of something to do to keep the plug covered from the salt-death-roads we have to deal with... Want to do this up on my car too? ;]

J

[fitzski]

Hiya John! You've been pretty quiet lately... haven't noticed you around too much?

LOL - it's not a big job... took maybe 20 mins; make it 5 if you have 1-3/4" hole saw... Have you done the 5.5L washer tank? That's a bit more significant...

[edco]

I just received mine today from www.boatersworld.com

Price was $19.99 plus $6.95 shipping

part number is 196740658

Love the concept. Thanks for the idea fitzski !

[pghPAtdi]

Man, this is awesome, wicked awesome. I think i've looked at this post a dozen times.

Dave

[K2 TDI]

Now if you incorporate a Kussmaul AutoEject unit that would be the cat's ass - the plug spits out and the flap closes when you start the car.
http://www.kussmaul.com/091-18wp-120.html

My TDI heater plug used to wedge nicely in the "rails" of the lower grill (where you mounted your covered receptacle). Unfortunately it no longer does, plus the plug cover disintgrated over a few CNY winters. For now, I've routed the exposed plug along the inside of the hood, passes from beneath the hood by the drivers side hood hinge, and daylights in a protected place beneath the rake of the trailing edge of the hood near the drivers side WW shaft.

[fitzski]

Actually... I did (briefly) consider one of those (or similar anyway)... They are used on firetrucks (and other emergency type equipment, I'd expect). They are huge, though. Something a bit more at home on the bumper of Cummins or Powerstroke...

But yeah - cool! I just want to see how far it ejects the plug!

[nicklockard]

Nice mod! I've got this on my list of mods now Damn you for giving me mod-itis tdiclub!

[kubo]

Originally Posted by pghPAtdi

Man, this is awesome, wicked awesome. I think i've looked at this post a dozen times.

Dave

booyah! same here. another simple, yet so usefull mod. things like these make me a tdiclub addict. I'm picking up mine today afternoon. Hats off for ingenuity. I have actually opened the Zerostart, and shortened the the power cable to make the install neater, and this will go very nicely with the setup.

[Voules]

Many thanks to Fitzski for this excellent modification and addition to the Zerostart. This takes about an hour to do. On the advice of Fitski I used a 1 3/4 bit ( the kind you use for drilling holes in doors for the passage sets) and drilled from the back of the grill. A little filing with a rat tail file, some black automotive Goop and voila; tighter than anything. No more fishing for the plug behind the bumper for me. I would highly recommend this one!!

[medrvmx5]

That is a sweet modification, ordered one of these plugs, hopefully get it soon, and now can get rid of the salted up plug in the grill and finally have some protection.

Tony