• Turn the ignition key to position 0.

  
  

  Note! Wait at least three minutes before unplugging the connectors or removing other electrical equipment.

  
  

• Remove the tunnel console's right-hand side panel by carefully pulling it away starting at the front edge. The side panel is secured with five clips on the inside.

• Uncover the right-hand side of the tunnel console's front section and the hole for the rubber grommet to the engine compartment by folding aside the passenger compartment carpet and the insulation panel underneath this.

• Undo the front screw in the mounting for the centre console.

• Take the bracket for the passenger compartment connector from the kit and tighten it in with the previously removed screw.

• Align the bracket so that it is straight and torque tighten the screw to 24 Nm (18 lbf.ft.).

• Fold the carpet back toward the bracket.

• Take a scriber and pierce a hole in the carpet opposite the two holes in the bracket.

• Take the passenger compartment connector socket and two screws from the kit and tighten the passenger compartment connector socket into the bracket.

• Press a locking sleeve (from the kit) onto the passenger compartment connector socket. Slide the locking sleeve as far along the terminal for the passenger compartment connector socket as possible.

• Take a carpet knife and cut a slit in the carpet just in front of the locking sleeve. Make the cut as long as the diameter of the locking sleeve.

  
  

  Note! Do not damage any wiring and hoses under the carpet.

  
  

• Remove the passenger compartment connector socket from the bracket and fold the carpet to one side.

• Remove the right-hand front wheel.

• Remove the screws in the front edge of the wing liner.

• Remove the plastic nut that holds the wing liner into the body.

• Fold the wing liner out of the way.

• Unscrew the screws and remove the engine splash guard.

• Remove the rubber seal in the cowl panel. It shall not be used again.

Clamping for 4-cyl. diesel engine shown

• Remove the cable to the engine heater from the three tie straps and the panel clip in the bracket for the cooling fan and the subframe.

• Remove the locking sleeve on the cable joint and separate the connectors.

• Take a cable tie with a clip for holes Ø 6.5 mm (1/4 ") from the kit and install it in the sub-frame.

• Press two clips from the kit into place on the sub-frame's upper edge.

• Lubricate the O-ring on the switch for the cable from the front engine block heater socket, and the O-rings on the joint connector with low temperature grease.

• Connect:

cable (1) from the front engine block heater socket

cable (2) to the passenger compartment connector socket

cable (3) to the heater.

• Take three locking sleeves from the kit and install them over the joints.

Clamping for 4-cyl. diesel engine D4164 shown

• Insert the junction connector in the space in the subframe. Secure the junction connector by fastening the cable tie through the rear hole of the connector.

• Install new cable tie in the clip in the upper edge of the sub frame instead of the one that was cut off.

• Install the cable in the bracket for the cooling fan using the cable tie.

• Tighten this clamp so that the cable rests against the clip and does not rub against the sub-frame.

• Press the cable into the panel clip. This may need to be moved.

Only applies to cars with 4-cyl. diesel engine D4164

• Thread the cut shorter section of the heat shield 110 mm (4 5/16 ") long onto the cable for the passenger compartment connector.

Only applies to cars with 4-cyl. diesel engine D4164

• Thread the cut shorter section of the heat shield 110 mm (4 5/16 ") long onto the cable for the passenger compartment connector.

Applies to all models

• Press the cable for the passenger compartment connector socket into both clips.

Only applies to cars with 4-cyl. diesel engine D4164

• The left clip should also hold the heat guard.

Applies to cars with EHPAS

Illustrations A and B

• Continue to route the cable around the corner on the sub-frame's right front corner and down to the servo hose on the right side of the sub-frame.

Applies to cars without EHPAS

• Take two cable ties with edge clips from the kit and press them onto the front right corner of the subframe as shown.

Illustrations A and B

• Cut the clip on two sides as shown in figure A and B.

Illustration A

Applies to cars with rivet nuts in the clip holes

• Screw the clips into the rivet nuts.

Illustration B

Applies to cars without rivet nuts in the clip holes

• Press the clips into the clips holes.

Applies to all models

Illustration A

• Pull up the cable in front of the subframe's right front corner, position it as shown and tighten the two cable ties.

Illustration B

• Continue routing the cable towards the inside of the subframe and clamp it using the two cable ties.

• Take the rubber grommet from the kit and cut away the very top of the largest rubber teat.

• Adjust the length of the cable from place where the rubber grommet should be located and out into the engine compartment so that it runs true and does not come into contact with any moving parts in the engine compartment. Conceal all cable excess under the mat in the passenger compartment.

• The radiation shield may need to be cut to fit the length of the cable between the clamp and the rubber lead-in in the firewall.

• Take the radiation shield from the kit and thread it on the cable to the passenger compartment connector. Pull the radiation shield onto the cable clamp.

• Grease the rubber grommet using low temperature grease in order to make it easier to insert the cable and rubber grommet into the hole in the cowl panel.

  
  

  Note! Do not get any grease on the surfaces of the connector.

  
  

• Thread the rubber grommet onto the cable.

• Insert the cable into the passenger compartment.

• Press the rubber grommet into the cowl panel.

• Take the grey tie strap from the kit and tighten the radiation shield upper end into the cable.

• Remount the wheel and tighten the wheel nuts to 140 Nm (103 lbf.ft.).

Illustration A

• Route the cable onto the bracket for the passenger compartment connector socket.

Illustration B

• Route the cable from the engine compartment through the hole in the carpet.

• Lubricate the O-ring using low temperature grease.

  
  

  Note! Ensure that no grease gets onto the connector surfaces.

  
  

• Connect the cable to the passenger compartment connector socket. Press a locking sleeve (from the kit) over the joint.

• Fold the carpet back into position and install the passenger compartment connector socket using both the screws.