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 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 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 (C70)

Installing the front intake (C70)

• Install the protective film along the outside of the bumper's left-hand corner.

• 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.

• Remove the screws to the air baffle.

• Press in the centre of the clips (1) and remove them. Remove the screws (2).

• Remove the left and right-hand front wheels.

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

• Detach the right and left-hand ends of the bumper.

• Grip the bumper from the inside and pull it forward in order to detach the two holders under the headlamps.

• Remove the bumper, unplug the connectors for the fog lamps and place the bumper on a surface that does not damage the paintwork.

  
  

  Hint Removal of the bumper is facilitated if carried out by two people.

  
  

• Unscrew and remove the bolt and nuts securing the wing liner.

• Remove the wing liner.

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

• Locate the pre-marking on the inside of the bumper cover on the left-hand side of the car.

• Use a Ø 10mm (3/8") drill bit to drill inside the four corners of the marking area.

• Take a sharp knife and carefully cut out the pre-marked area in the bumper cover on the left-hand side of the car.

  
  

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

  
  

• Remove swarf and smaller irregularities with a file. Do not damage the paintwork and follow the pre-marking accurately.

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

• File down the edges of the holes.

• Take the cable harness with front socket and box from the kit.

• Route the cable through the box and fit the connector.

• Pull in the cable and align the box in the hole made in the bumper.

• Take the bracket and the large plastic nut from the kit and thread the cable harness through them.

• Pull forward the bracket to the inside of the bumper and tighten the box with the large plastic nut. Plug the electrical connector into the front socket as a counterhold for when the latter is tightened.

• Check that the connector cover works as intended.

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 front intake cable from the front edge of the washer fluid reservoir, along the bottom edge of the front member and over the drive shaft. Route the cable a bit into the engine compartment.

• Press the cable into the previously installed clips.

• Take a clip (1) 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 Ø4 mm (5/32 ”) hole for the ground lead, on the outside of the left-hand front member, approximately as illustrated.

• 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.

• Pull the engine cover up at the front edge so that the three catches (1) on the underneath release.

• Remove the engine cover by pulling it forwards until the mounting (2) underneath releases.

• Remove the front large nut at the battery terminal on the starter motor.

• Remove the two upper screws for the starter motor.

• Remove the lower screw for the starter motor.

• Pull the starter motor from its mounting in the engine and turn it to access the electrical connections.

• Remove the small nut and disconnect the last electrical connection.

• Remove the starter motor from underneath the car.

• Detach the coolant hose from its clamp and secure it below the core plug.

• Hit the middle of the core plug on cylinder number two using a center punch.

• Use puller, P/N 9512960 to remove the core plug.

• Install the expander in the core plug and tighten.

  
  

  Caution! Tighten to 10–25 Nm (7–18 lbf. ft.), max. 40 Nm (30 lbf. ft.). Tightening more than this may damage the expander.

  
  

• Install the mounting bracket. Remove the core plug.

  
  

  Note! There may be some coolant left in the engine.

  
  

• Reinstall the coolant hose in its clamp.

• Remove the screw in the tensioner for the hose connection in cylinder number three.

• Lubricate the O-ring on the engine block heater using low temperature grease.

• Press the engine block heater into the hole for the core plug with the angled section of the heating element pointing down.

• Tighten the engine block heater to the engine block using the tensioner and screw from the kit. (the tensioner is positioned above the tensioner).

• Torque tighten the screw to 10 Nm (7.5 lbf.ft.).

• Grease the O-rings on all the engine block heater cables using low temperature grease P/N 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.

  
  

Illustration A

• 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.

Illustration B

• Route the cable (1) from the engine block heater, over the transmission where it is secured at the engine, and to the drive shaft where the front intake's cable (2) is located.

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 connector

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), P/N 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 cable (1) from the engine block heater, to the pre-routed cable (1) from the front intake. (At the same time as installing the passenger compartment connector socket/timer relay, install the bracket and mounting with the junction connector/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.

• Remove the sprung guide sleeve from the starter motor's mounting flange at the transmission.

• Install the guide sleeve in the starter motor's mounting flange. Press it in so that it reaches the bottom of the hole.

• Reinstall the starter motor.

• Tighten the three M10 screws. Tighten to 35 Nm (26 lbf.ft.).

• Tighten the M8 nut to the batter terminal. Tighten to 12 Nm (9 lbf.ft.).

• Tighten the M6 nut to the batter terminal. Tighten to 6 Nm (4.5 lbf.ft.).

• Reconnect the battery negative lead

• 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.

Bleeding and filling the cooling system Illustration A

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

Illustration B

• Install the bleed kit P/N 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. Tighten the wheel nuts. Tighten to 90 Nm (66 lbf.ft.).

• Reinstall the engine cover.