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 isopropanol to clean the bumper cover where the cutting template for the front intake is to be secured.

• Wipe dry.

• Use the template from the installation instructions.

• Cut out following the dotted lines.

• Secure the template edge-to edge with the line at the front edge of the wing and lower edge of the bumper shell.

Accessory installation

• 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 cover.

• Remove the template and tape pieces.

• 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.

• Ensure that the front intake cover opens rearwards.

Removal

Accessory installation

• Route the cable with ground lead from the front intake behind 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 the ground cable.

• Clamp the cable in the hole in the subframe's front mounting.

• Drain the coolant.

• Tighten the nipple after use.

• Take two clips from the kit and install them on the upper edge of the subframe, turned in toward the subframe U-profile. Install the clips in the positions illustrated.

• Detach the double clamp on the cable to the alternator that is located on the thermostat housing hose.

• Rotate the catch on the thermostat housing pipe anticlockwise. Detach the hose and drain the remaining coolant.

• Cut off the hose using a sharp knife in accordance with the measurements. Make the incision as straight as possible. The short hose-end that was cut off shall be used again.

• Cut out the short cut-off hose section as illustrated.

• Discard the cut-off hose bend.

• Remove the short hose-end and press it on the pipe that runs to the thermostat housing. Make sure that the cut-out in the hose connection is turned down and fits into the corresponding pin in the pipe connection.

• Rotate the catch on the pipe clockwise against the stop.

• Take a hose clamp from the kit and install it on the hose-end.

• Take the engine block heater, bracket, rubber coated clamp and screw from the kit and assemble them as illustrated.

• Do not tighten the screw yet.

• Take the hose clamp from the kit and fit it onto the engine block heater's upper connection.

• Position the engine block heater with bracket in the front edge of the oil sump and connect both hose-ends to the engine block heater's connections.

• Take a screw from the kit and tighten the bracket with engine block heater into the existing hole in the oil sump.

• Now adjust the engine block heater in the rubber coated clamp so that the hoses are properly fitted on the engine block heater's connection.

• Tighten the screw to the rubber coated clamp.

• Tighten the hose clamps to the engine block heater.

• Install the double clamp to the cable for the alternator in the engine block heater's upper hose.

• Lubricate the O-ring on the connector for the heater's cable with low temperature grease P/N 1161427.

• Connect the cable from the front engine block heater socket to the engine block heater and press it in firmly.

• Press a locking sleeve from the kit over the cable splice.

• Take a double tie strap and clamp the joint cable into the pipe that runs to the thermostat housing.

Applies when fitting passenger compartment connector at the same time

• Take the locking sleeves from the kit.

• Connect the cables in accordance with the following:

  Cable (1) from the engine block heater.

  Cable (2) joint cable to the passenger compartment connector socket.

  Cable (3) from the front engine block heater socket.

• Press the cables firmly into the junction connector and press the locking sleeves in over the cable splices.

• Firmly press together the cable from the engine block heater and the cable from the front engine block heater socket and press in a locking sleeve from the kit over the cable splice.

• Press the cable into the two clips and tighten the cable splice to the existing cable harness.

Installation

• Fill with coolant, run the engine to operating temperature, bleed the cooling system and check that there are no leaks.

• Top up the cooling system as required.