Preparations

Preparations

• Turn the ignition key to position 0.

• Disconnect the battery negative lead.

• Remove the cover from the air filter.

• Press in the catches on the control module connectors, twist up the lock arms and pull out the connectors.

• Remove the two screws (1) from the induction pipe of the air filter.

• Detach the hose clamp (2).

• Remove the intake manifold from the air cleaner (ACL) and place it to one side.

• Lift up the air filter, which sits with a clip on the left side. Position the air filter in the engine compartment so that the grounding point underneath is accessible.

• Detach the left-hand headlamp by pulling up the two locking pins and then carefully pulling away the headlamp forwards.

• Carefully prize up the catch on the connector for the headlamp using a screwdriver.

• Pull the catch up completely, detach the connector and place the headlamp to one side.

Installing the auxiliary lights bracket

Installing the auxiliary lights bracket

Illustration A

• Take the cable harness from the kit and position it with relay and relay holder where the air cleaner (ACL) was located.

• Route the cable ends without calbe terminal along the left side of the plate flange on the left side member.

Illustration B

• Route the cable harness to the right of the top of the bumper rail and out through the third lower space in the air intake above the number plate holder.

Remove:

• the number plate

• the screws (1) to the number plate holder.

• the number plate holder.

• Take the auxiliary lights bracket (1) from the kit and secure it in the holes for the number plate holder. Use the upper holes (2) in the auxiliary lights bracket.

• Drill with a Ø 7 mm (9/32") diameter drill bit in the centre of the holes (3), through the bumper cover and the bumper rail that is 39 mm (1 1/2") inside.

  
  

  Note! Keep the drill horizontal.

  
  

• Remove the screws and auxiliary lights bracket.

• Drill the holes (1) with a drill bit (part no. 8633152), through the plastic with the thicker section of the drill bit, and through the bumper rail (2) with the thinner section of the drill bit, which has the dimension Ø7.3 mm (19/64").

  
  

  Note! It is important that the tip of the drill bit meets the hole that was previously drilled into the bumper rail. The flat surface on the drill bit must drill out all plastic up to the bumper rail.

  
  
  

  Note! Hold the drill horizontally. Use a torch to check that there is no plastic swarf in the holes.

  
  

• Check that the surface (1), which the socket shall support against, is free from plastic.

• Install two spacer sleeves L=50 mm (2") into the holes.

  
  

  Note! The spacer sleeves must protrude approx. 5.5 mm (7/32") from the bumper cover.

  
  

• Affix tie straps (1) in the holes in the auxiliary lights bracket, but do not tighten.

• Install the auxiliary lights bracket on the bumper using the screws (2) from the kit. Tighten loosely. The screws create their own threads in the drilled holes, which means that they may screw in stiffly.

• Guide in the two cable ends (1) in the three tie straps (2). Route the cables as illustrated.

• Adapt the length of the cable to the lamps. Press back any excess length of the cable outside of the front grille in through the front grille.

• Tighten the tie straps.

• Tighten the two screws for the auxiliary lights bracket.

• Install a spacer washer (3) between the auxiliary lights bracket (4) and the bumper shell (5) on both sides.

• Reinstall the number plate holder and fasten it with the two screws.

• Reinstall the number plate.

Installing auxiliary lights

Installing auxiliary lights

• Remove the screw (1) and the cover.

• Press lightly on the lens (2).

• Fit a screwdriver (3) between the insert and the lamp housing, and prize carefully.

• Install the lamp housing on the auxiliary lights mounting with screw and nut. Tighten manually.

• Route the cable harness with rubber grommet (1) through the holes in the lamp housing.

• Press the rubber grommet into the hole.

• Install the cable terminals from the kit on the two cable ends.

• Connect the blue (BL) cable to the lamp's cable, with a connector socket housing in between.

• Connect the black (SB) cable to ground on the light insert.

• Assemble the auxiliary light, as illustrated.

Cable routing and connection

Cable routing and connection

Illustration A

• Take the previously routed cable harness (1) and route it as illustrated.

Illustration B

• Plug the connector (2) into the pre-routed connector (3).

Illustration C

• Press in the relay (4) at the vertical panel, under the panel that the main headlamp rests on. Rotate the relay up so that the connector with the cable does not make contact with panel underneath. See also illustration 8 for the location of the relay.

Illustration A

Applies to cars with 5-cylinder and 8-cylinder engines

• Slacken the existing screw in the air filter bracket and connect the ground cable - tightening torque: 24 Nm (18 lbf.ft.).

Illustration B

Applies to cars with 6-cylinder engine

• Remove the ground screw from the kit and fasten the ground cable to the centre welding nut - tightening torque: 24 Nm (18 lbf.ft.).

Applies to all models

• Twist down the ground cable terminal and position the cable so that it is not pinched by the air filter when it is reinstalled. Route any excess cable through the front grille and clamp at existing cables behind the headlamps with tie straps.

• Reinstall the air filter.

• Connect and reinstall the control module.

• Refit the cover over the air filter.

• Reinstall the intake manifold. Tighten the two screws to 10 Nm (7.5 lbf.ft.).

• Plug in the connector to the headlamp and reinstall the headlamp.

  
  

  Note! The longer of the locking pins must be located on the outside of the headlamp.

  
  

• Remove the cover from the fuse box in the engine compartment. Install a 20A fuse in position 5.

• Reinstall the cover.

Installing the switch

Installing the switch

Illustration A

• Remove the cover plug to the 12V socket.

• Insert a scriber with an angled tip into the joint on the underside, at one side of the keypad surround.

Illustration B

• Carefully pull out the surround using the scriber, pull along the underside of the surround. It is secured with three mounting lugs in the top and bottom edges.

  
  

  Note! Do not damage the surround.

  
  

• Place the surround to one side.

• The switch can be located in any available position. Remove the dummy button and install the new switch (1).

• Reinstall the surround and cover plug to the 12V socket.

Finishing work

Finishing work

• Turn the ignition key to position II.

• Reconnect the battery negative lead

• Align the auxiliary lights for optimum beam pattern.

• Tighten the two screws.

• Install the protective caps on the screw heads.

Installing the top struts

Installing the top struts

• Take the top strut and insert one end in the space between the two bumper sections. Position it in line with the centre of the auxiliary light.

• Mark out for drilling the hole through the top strut and in the bumper, in the centre of the black edge (A).

• Drill out the hole using a Ø3 mm (1/8") diameter drill bit.

• Remove any swarf.

• Mark out for drilling the hole through the top strut and in the centre top/rear edge of the auxiliary light.

• Drill out the hole using a Ø 4.5 mm (3/16") diameter drill bit.

• Remove any swarf.

• Take the top strut and locate it between both of the drilled holes for cutting the strut (1).

• Shorten the strut (1) to a suitable length.

• Tighten the top strut to the bumper and auxiliary light with screws, nuts and toothed washers.

• Bend the top strut down to the bumper using a screwdriver. This is so that the lower edge of the bonnet does not catch when it is closed.

• Clean the painted surfaces in the front and lower edges of the bonnet opposite where the top struts are mounted in the bumper. Use a mixture of 30% washer fluid and 70% water.

• Wipe dry.

• Firmly press the protective tape into place in the front and lower edges of the bonnet, opposite where the top struts are mounted in the bumper.