Did a search for "block heater" and found this thread. As I type, I'm in the midst of a hassle putting one in. No problem getting the frost plug out, removed the exhaust manifold with no problems for clear shot at the right rear most frost plug on my B230F non turbo. A few "brrrrp!"s from an air chisel loosened it, drilled a hole for a pry point but didn't really need it. Came out OK. The problem is the heater. Local Southern CO parts house stocks "Kat's" heaters. Their listed model was a 44mm, about a quarter inch too large diameter it turned out. My frost plug is 40mm and the element MUST be short and angled away from the block opening. About 16/32nds inside the block is the #4 cylinder casting. Not much room at all. Another closer parts house also had Kat's and took the frost plug to them for measurements. Found one with a possible element orientation. Got home, no go. Element hits the cylinder casting before seating. Above NAPA link is down according to NAPA. One more day off tomorrow, will try some more options, maybe in Colorado Springs. Can't find a frost plug repair insert even to close the block so I can use the car. The original Kat's block heater instructions only went up to '84 which should have been a warning; the instruction sheet said orient the element at "9:00" position FYI. Sigh. Will try and post back results and outcome. Have to be at work at 0500hrs on Wednesday. No pressure...
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