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

• Remove the right-hand front wheel.

• Remove the five screws in the leading edge of the wing liners on both sides.

• Remove the plastic nuts that hold the wing liners at the body on both sides.

• Fold the wing liners to one side on both sides.

• 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.

• Apply the template edge to edge with the line at the front edge of the front wheel arch and lower edge of the bumper cover.

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 the subframe's left-hand front mounting.

• Continue downwards on the inside of the subframe.

• Clamp the cable in the hole at the left-hand front mounting in the subframe.

• Drill a Ø4mm (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.

• Drain the coolant.

• Tighten the nipple after draining.

• Remove the hose clamp, pull loose the hose from the oil cooler and let the remaining coolant drain.

• Install the hose again and cut it off approx. in the middle of the straight hose elbow.

• Pull loose the hose end and throw it away. New hose and nipple are included in the kit.

• Get a junction nipple from the kit and insert half of it in the remaining hose part.

• Take hose clamp from the kit and tighten down the nipple.

• Tighten the hose clamp securely.

• Take a bracket, two bolts and washers from the kit. Fasten the bracket in the existing holes on the left side of the oil cooler.

Applies to vehicles with 2 wheel drive

• Take the heater, rubberized clamp and bolt from the kit. Fasten the heater with the clamp in the upper hole in the bracket. The hose connections on the heater should point backwards.

Applies to vehicles with 4 wheel drive

• Take the heater, rubberized clamp and bolt from the kit. Fasten the heater with the clamp in the lower hole in the bracket. The hose connections on the heater should point backwards.

Applies to all vehicles

• Get junction cable and two hose clamps from the kit.

• Cut off the hose as illustrated.

• Install the hose between the earlier installed junction nipple and the upper connection in the engine heater.

• Tighten the clamps securely. Make sure that the hoses do not rub against the drive shaft or hose clamps.

• Get the last junction hose and the two remaining hose clamps from the kit. Connect the junction hose between the remaining connections in the engine heater and the oil cooler.

• Tighten the clamps securely.

• Take the clip with cable tie for a Ø 6.5 mm (1/4 ") hole and press it into the left hole on the inside of the upper edge of the subframe.

• Take four clips from the kit and press them into place on the upper/front edge of the subframe.

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

Applies when only the engine block heater is installed

• Connect the extension 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.

• Clamp the cable splice (1) to the inside of the subframe using the tie strap and press the cable into the clips.

Applies when fitting passenger compartment connector at the same time

• Connect:

cable (1) from heater

cable (2) to the passenger compartment connector socket

cable (3) to the front inlet

• Insert the junction connector in the space in the sub-frame and tighten down the junction connector around the rear cable with a cable tie in the hole at the top of the sub-frame.

Applies to all vehicles

• Continue to pull the cable up around the subframe's right-hand mounting between the power steering pump and body.

• Continue to pull the cable down along the hose to the power steering pump to the inside of the subframe.

• Clamp using cable ties with clips.

• Route the cable along the inside subframe and up towards the heater.

• Press two clips onto the edge and secure the cable.

• Take the radiation shield from the kit and thread it on the extension cable.

• Press the routed extension cable fully into the heater and press a lock sleeve over the splice.

• Reposition the radiation shield so that it covers the entire heater connector.

• Fasten the radiation shield to the heater's connector with the grey cable tie from the kit.

Installation

• Fill with coolant and warm up the engine. Bleed the cooling system and check for leaks. Top up the cooling system as necessary.