Color symbols

1. Used for focused part, the part that you are to do something with.

2. Used as extra colors when you need to show or differentiate additional parts.

3. Used for attachments that are to be removed/installed. May be screws, clips, connectors, etc.

4. Used when the component is not fully removed from the vehicle but only hung to the side.

5. Used for standard tools and special tools.

6. Used as background color for vehicle components.

Removal

• Use the template from the installation instructions.

• Cut out following the dotted lines.

Accessory installation

• Attach the template using tape edge to edge with the embossing to the front wing and the embossing in the bumper cover as illustrated.

• Take a sharp knife. First make a thin cut along the edges of the inside of the template. This provides a groove to follow. Then cut carefully out of the bumper covers.

• Remove the template.

• Install the protective cover for the front engine block heater socket from the kit. Check that it aligns. Adjust the hole using a knife or file as necessary.

• Smooth off the hole edges. Remove any swarf.

• Press the protective cover (from the kit) into place in the hole cut in the bumper cover.

• Take the cable for the front engine block heater socket with ground lead from the kit and thread them through the protective cover.

• Install the attaching brace and nut from the kit.

• Plug the electrical connector into the front engine block heater socket. Use the connector as a counterhold when tightening.

• Tighten the front engine block heater socket to the bumper shell.

• Press the cable into the holder on the washer fluid reservoir.

• Remove the cover on the radiator expansion tank.

• Ensure that the front intake cover opens rearwards.

• Route the cable with ground lead from the front intake in front of the subframe's left-hand front mounting.

• Continue downwards on the inside of the subframe.

• Drill a Ø4 mm (Ø5/32") hole for the front intake grounding on the underside of the left front side member as illustrated.

• Deburr the hole edges, remove the drill swarf and apply rustproofing agent.

• Take a screw and toothed washer from the kit. Tighten in the ground cable.

• Drain the coolant.

• Tighten the nipple after draining.

• Remove the retaining clip which holds the plug in the coolant pipe on the right-hand side above the drive shaft.

• Pull out the plug and drain the coolant.

• Remove the sealing ring in the coolant pipe and check that it is intact. Replace if necessary.

• Lubricate the sealing ring with low temperature grease.

• Reinstall the sealing ring in the coolant pipe.

• Take the heater from the kit and press it into position on the coolant pipe, and lock it with the retaining clip.

• Check that the heater is fitted securely.

• Turn the heater so that it is clear of the surrounding components.

• Take the radiation shield from the kit and cut it to a length of 240 mm (9 7/16").

• Take the jointing cable and the heat shield from the kit.

• Thread the heat shield on to the jointing cable.

• Lubricate the O-ring on the connector on the jointing cable with low temperature grease.

• Take the jointing cable and press it firmly into the engine block heater's connector. Then press a locking sleeve from the kit over the joint.

• Pull the radiation shield down so that it fully covers the connector on the heater.

• Take the grey tie strap from the kit and tighten the radiation shield at the bottom to the heater.

• Route the cable from the engine block heater to the left toward the thick cable harness at the starter motor and up where the gearbox is connected to the engine. Route the cable to the front side of the engine/gearbox.

• Secure the wiring at the existing thick cable harness. Use the tie strap from the kit.

• Route the cable down from the gearbox mounting in the engine to the front side of the gearbox along the turbocharger pipe.

• Clamp the cable at the thick cable harness on the right hand side of the air cleaner with a tie strap.

• Continue and clamp the cable at the turbo charger pipe with the double tie strap.

• Take the clip with cable tie for a Ø6.5 mm (1/4 ") hole and press it into the left hole on the inside of the upper edge of the subframe.

• Take the two clips from the kit. Press them onto the subframe's upper/front edge and at the left front-edge of it, according to the dimensions in the illustration.

• If the passenger compartment switch is installed at the same time, the position of the right hand clip must be adapted to the junction connector that is supplied.

• Lubricate the O-ring on the connector for the cable from the front intake, and if the car is to have a passenger connection, also the O-rings on the junction switch with low temperature grease.

Applies when only the engine block heater is installed

• Connect the jointing cable of the engine heater with the cable from the front intake. Press the connectors together and press a locking sleeve from the kit over the splice.

• Pres the cable from the front intake in the two clips in the upper edge of the sub-frame and clamp the cable joint on the inside of the sub-frame using the tie-strap.

• Clamp the cable at the stay for the engine cooling fan using the tie strap and in the upper corner of the sub frame with the clip tie strap. Ensure that clamp's clip is positioned so that the cable is fixed against this and does not rub against the sub-frame.

Applies when fitting passenger compartment connector at the same time

Connect:

• cable (1) from the front intake

• cable (2) to the passenger compartment connector socket

• cable (3) to the heater

• 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 the cable in the other clamps in the same way as in point B.

Applies to all vehicles

Installation

• Install adapter P/N 9512955 in the expansion tank. Tighten.

• Install the bleed kit P/N 9512957 on the connection nipple for the adapter.

• Bleed and fill the cooling system. See the manual for the bleed kit.

• Test drive and check that there are no leaks.