Installing the front intake, applies to the S40/V50, MY -07

Installing the front intake, applies to the S40/V50, MY -07

• Use isopropanol P/N 1161721 to clean the bumper shell where the cutting template for the front engine block heater socket is to be secured.

• Wipe dry.

• Apply a piece of tape vertically to the bumper cover. See the illustration.

• Remove the backing tape on the template from the kit.

• Press the template onto the embossing on the bumper cover. The marking (1) on the template must be opposite the front edge of the tape. The marking (2) on the template must be in line with the curve (3) at the top edge of the embossing on the bumper cover.

• 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.

  
  

  Note! Cut carefully. It is easy to slip with the knife and move outside the template.

  
  

• 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.

• Remove the seven screws holding the engine splash guard and remove the guard.

• Remove the left front wheel.

• Remove the five screws holding the bumper shell in the fender liner on the left and right-hand sides.

• Remove the nut holding the left-hand fender liner to the front member.

• Bend the front edge of the left-hand fender liner up over the brake calliper.

• Push in the centre of the five clips (1). Remove the clips.

• Remove the two screws (2).

Illustration A

• Remove the covers for the nozzles for the headlamp washers on the right and left-hand sides. Carefully grip the cover. Pull the cover out until the catch becomes accessible.

Illustration B

• Press the catch up. Remove the cover. Do not damage the painted surfaces or the washer nozzles.

• Detach the ends of the bumper shell on the left and right-hand sides. Grasp the end of the bumper shell inside the fender liner. Carefully pull the end of the bumper shell so that the two catches on the inside release.

• Remove the bumper cover and air baffle. Pull the bumper cover and air baffle forwards until the remaining catches under the lamps release.

• Disconnect the connectors for the fog lamps and parking assistance if applicable.

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

• Insert the cable for the front engine block heater socket together with the ground lead from the kit through the protective cover.

Illustration A

• Install the mounting and nut from the kit. Connect the connector to the front engine block heater socket. Use the connector as a counterhold when tightening.

Illustration B

• Turn the connector for the front engine block heater socket so that the cover opens forwards. Tighten the front engine block heater socket to the bumper cover.

Installing the front intake, applies to the S40/V50, MY 07-

Installing the front intake, applies to the S40/V50, MY 07-

• Remove the seven screws from the engine splash guard.

• Remove the left front wheel.

• Remove the five screws holding the bumper shell in the fender liner on the left and right-hand sides.

• Remove the four screws.

• Push in the centre of the five clips (1). Remove the clips.

• Remove the two screws (2).

• Remove the covers for the nozzles for the headlamp washers on the right and left-hand sides. Carefully grip the cover. Pull the cover out until the catch becomes accessible.

• Press the catch up. Remove the cover. Do not damage the painted surfaces or the washer nozzles.

• Detach the ends of the bumper shell on the left and right-hand sides. Grasp the end of the bumper shell inside the fender liner. Carefully pull the end of the bumper shell so that the two catches on the inside release.

• Remove the bumper cover and air baffle. Pull the bumper cover and air baffle forwards until the remaining catches under the lamps release.

• Disconnect the connectors for the fog lamps and parking assistance if applicable.

• Using a sharp knife, first make a thin cut along the edges of the new marking inside of the bumper cover. Then carefully cut out the bumper cover hole.

  
  

  Note! Cut carefully. It is easy to slip with the knife and move outside the markings.

  
  

• 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.

• Take the protective cover from the kit and press it into 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 mounting and nut from the kit. Connect the connector to the front engine block heater socket. Use the connector as a counterhold when tightening.

• Turn the front intake's connector so that the cover opens forward.

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

Installing the front intake, applies to the C30

Installing the front intake, applies to the C30

• Use isopropanol P/N 1161721 to clean the bumper shell where the cutting template for the front engine block heater socket is to be secured.

• Wipe dry.

• Find the template for the C30 in the installation instructions. Cut it out following the dotted lines.

Illustration A

• Position the template in the corner of the bumper cover embossing and align it against the upper edge of the right-hand edge.

Illustration B

• Tape the template to the bumper cover.

• 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.

  
  

  Note! Cut carefully. It is easy to slip with the knife and move outside the template.

  
  

• 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.

• Remove the seven screws from the engine splash guard.

• Remove the left front wheel.

• Remove the four screws holding the bumper cover in the wing liner on the left and right-hand sides.

• Remove the nut holding the left-hand fender liner to the front member.

• Bend the front edge of the left-hand fender liner up over the brake calliper.

• Push in the centre of the five clips (1). Remove the clips.

• Remove the two screws (2).

Illustration A

• Remove the covers for the nozzles for the headlamp washers on the right and left-hand sides. Carefully grip the cover. Pull the cover out until the catch becomes accessible.

Illustration B

• Press the catch up. Remove the cover. Do not damage the painted surfaces or the washer nozzles.

Illustration A

• Apply a piece of tape to the panel of the wing edge to protect it.

• Carefully pry off the corner of the bumper cover using a weatherstrip tool until the three hooks on the inside release.

Illustration B

• Remove the bumper cover with air baffle by grasping the ends and pulling forwards until the remaining hooks under the lamps release.

  
  

  Note! Get help from a colleague for this procedure.

  
  

• Disconnect the connectors for the fog lamps or parking assistance if applicable.

• Remove the pieces of tape from the edges of the wing.

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

• Insert the cable for the front engine block heater socket together with the ground lead from the kit through the protective cover.

Illustration A

• Install the mounting and nut from the kit. Connect the connector to the front engine block heater socket. Use the connector as a counterhold when tightening.

Illustration B

• Turn the connector for the front engine block heater socket so that the cover opens backwards. Tighten the front engine block heater socket to the bumper cover.

Installing the front intake, only applies to the C30 2010-

• Remove the screws and the plastic nut from the left-hand inner wing

• Carefully pry off the panel all the way around. Place it to one side. A new panel can be found in the kit.

Illustrations A and B

• Take a new panel, front intake cable with washer and nut from the kit.

  
  

  Note! The washer must be positioned as illustrated.

  
  

• Route the cable and ground lead through to the engine heater.

  Ensure the connector is turned so that the cover's sides are parallel with the plates in the panel and that the cover opens from the panel's left-hand side (Image B).

• Tighten the connector.

• Insert the cable through the oval smaller of the holes behind the panel.

• Press the panel into place.

Cable routing

Cable routing

• Install three clips from the kit on the panel edge on the underside of the left front member.

• Reinstall the bumper cover. Use the five clips and the two screws at the top edge. Ensure that the air baffle is correctly positioned in its mounting.

• Reconnect the connectors for the fog lamps and parking assistance if applicable.

• Press the ends of the bumper shell into place on the body.

• Route the cable for the front engine block heater socket from the front edge of cover for the control module, along the underside of the front member and over the drive shaft.

• Press the cable into the previously installed clips.

• Take a clip from the kit. Press the clip into place at the edge of the panel. See the illustration.

• Press the cable into the clip.

• Clamp the cable in the hole in the bracket for the front left radiator mounting. Use a tie strap (1) from the kit.

• Drill a Ø 4 mm (5/32 ”) hole for the ground lead, on the outside of the left-hand front member, approximately as illustrated.

• Remove any swarf.

• Treat the edges of the holes using a rust-proofing agent.

• Secure the ground lead in the drilled hole. Use the screw and toothed washer from the kit.

• Secure the excess ground lead at the clamp for the heater cable.

Installing the engine block heater

Installing the engine block heater

• Remove the cover on the radiator expansion tank.

• Unscrew the drain nipple in the left-hand bottom edge of the radiator. Drain the coolant.

• Remove the engine cover over the engine by pulling it straight up so that it releases from the three rubber catches on the underneath.

Illustration A

• Remove the four screws to the heat deflector plate above the manifold.

Illustration B

• Fold away the heat deflector plate from the left-hand side of the manifold.

  
  

  Note! Be careful with the cable to the heated oxygen sensor.

  
  

• Detach the connector to the heated oxygen sensor as required.

• Remove the plug in the engine block, under the left-hand side of the manifold, use a Hex socket, part no. 9512965.

  
  

  Note! There is a small amount of coolant remaining in the engine.

  
  

• Take the heater from the kit and brush sealing paste, part no.1161056, on the threads.

• Tighten the heater in the hole in the engine block, use wrench. part no.9997158. Angle it so that it engages in the transmission's mounting flange on the engine.

• Grease the O-rings on all the engine block heater cables using low temperature grease part no. 1161417. If the car is to have a passenger compartment connector socket/junction connector/timer relay, also grease the O-rings on these components.

  
  

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

  
  

• Connect the cable (1) from the kit to the engine block heater.

• Firmly press the cable junction together. Press a locking sleeve from the kit over the cable junction. Ensure that the cable does not rub against sharp edges or moving parts in the engine compartment.

• Take the heat deflector hose from the kit and cut it to a length of 200 mm (7 7/8").

• Thread the heat deflector hose onto the cable right up to the heater, so that it covers the whole connector on the heater.

• Take the grey tie strap (1) from the kit and clamp the heat deflector sleeve at the upper edge.

• Pull the cable (1) from the engine block heater, over the gearbox and on to the drive shaft where the front socket cable (2) is located.

• Press in a clamp (3) from the kit at the edge on the bracket for the gear selector cables.

• Press the cable into the clamp.

Applies to cars where the engine block heater and/or passenger compartment connector socket/timer relay are mounted at the same time

• Take the bracket and the rubber guard from the kit for the passenger compartment connector socket. Press the rubber guard on to the bracket.

Applies to cars where the engine block heater and passenger compartment connector socket are installed at the same time

• Tighten the junction connector at the bracket (included in the kit for the passenger compartment connector socket) in the position illustrated. Use the screw, toothed washer and nut from the kit. The bracket must be parallel to the length of the junction connector.

Position (1) cable for the engine block heater

Position (2) cable for the passenger compartment socket

Position (3) cable from the front engine block heater socket.

Applies to cars where the engine block heater and timer relay are installed at the same time

• Tighten the timer relay at the bracket (purchased separately) in the position illustrated. Use the screw, toothed washer and nut from the kit. The bracket must be parallel to the length of the timer relay.

• Connect the connector on the long cable harness (from the kit) to the timer relay.

• Press the rubber plug (1), part no. 346509, (purchased separately) into place on the free socket in the timer relay. Use butyl tape to secure the rubber plug.

Position (2) cable for the engine block heater

Position (3) cable from the front engine block heater socket.

Applies to cars where the passenger compartment connector socket and the timer relay are installed at the same time

• Tighten the timer relay at the bracket (purchased separately) in the position illustrated. Use the screw, toothed washer and nut from the kit. The bracket must be parallel to the length of the timer relay.

• Connect the connector on the long cable harness (from the kit) to the timer relay.

Position (1) cable for the passenger compartment socket

Position (2) cable for the engine block heater

Position (3) cable from the front engine block heater socket.

• Connect the short cable from the kit to the engine block heater, to the routed cable (1) from the front socket. (When fitting junction connector/timer relay at the same time, the cable from the front socket is connected to the single outlet on the junction connector/timer relay instead. Refer to the installation instructions for passenger compartment socket/timer relay).

• Firmly press the cable junction together.

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

• Take a double tie strap from the kit. Install the double tie strap around the stay and the cable splice. Ensure that the splice is secured in the centre of the strut. Tighten the double clamp properly.

• Refit the heat deflector plate and torque tighten the screws to 10 Nm (7 lbf. ft.).

• Reinstall the left-hand fender liner. Tighten the fender liner to the left-hand side member.

• Tighten the two fender liners to the bumper shell on the right and left-hand sides.

• Refit the covers to the nozzles for the headlamp high-pressure washers.

Bleeding and filling the cooling system

Illustration A

• Install adapter part no. 9512955 in the expansion tank. Tighten.

Illustration B

• Install the bleed kit part no. 9512957 on the connection nipple for the adapter.

Illustration C

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

• Reinstall the engine splash guard.

• Reinstall the front wheel and tighten the wheel nuts to:

Step 1: 20 Nm (15 lbf.ft.)

Step 2: 110 Nm (81 lbf.ft.)