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.

• Rotate the front wheels so that the bolts in the wheel arch liner on the left and right side are accessible.

• Remove the seven screws in the front edge of the wheel arch liner on the left and right sides.

• Remove the plastic nut holding the wheel arch liner to the body on the left and right side.

• Remove the engine splash guard.

• Clean the marked area.Soap solution.

• Use: soap solution

• Wipe dry.

• Use the template from the installation instructions.

• Cut out following the dotted lines.

• Attach the template edge to edge with front edge of the front wing and the joint in the bumper cover as illustrated.

• 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.

• 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.

• Fold the wing liner out of the way.

• 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.

• Press the cable into the holder on the washer fluid reservoir.

• Ensure that the front intake cover opens rearwards.

• Route the cable with the ground lead from the front intake in front of the subframe's left front mounting.

• Continue downwards on the inside of the subframe.

• Drill a Ø 4mm (5/32 ") 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 and tighten in the ground cable.

• Turn the drain valve counter-clockwise and drain the coolant.

• Tighten the valve when the coolant has drained.

• 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 tie strap 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.

• Take the extension cable from the kit. Lubricate the O-ring on the connector with low temperature grease P/N 1161427.

• Do the same with the O-ring on the connector of the front intake cable.

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

If the accessory passenger compartment connector is to be installed at the same time, install the junction connector now and lubricate the O-rings of the connector as described earlier.

• 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

• Take a cable tie with edge clips from the kit and press onto the metal edge on the front right corner of the sub-frame, as shown.

Applies to all models

• Take two clips with tie straps for a Ø 8mm (5/16 ") hole from the kit and press them into the two holes on the inside right of the subframe.

• Fold aside and attach the trailing edge of the wheel housing's right fender liner for better access when installing the two double-ties for the heater's cable.

• Install edge clips as illustrated.

• Take two double cable ties and secure them at the lower engine mounting. The front tie around the plastic stay (1) and the rear one through the rubber bushing (2).

• Pull up the cable in front of the subframe's right-hand front corner, position it according to the image and tighten the tie loosely.

• Continue routing the cable along the inside of the subframe and secure it with the two tie straps - do not tighten fully yet.

• Route the cable rearward along the sub-frame and to the heater. Fasten the cable in the two double cable ties but do not tighten fully yet.

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

Applies to AWD

• 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.

• Adjust the cable in the cable ties from the heater toward the front right corner of the subframe. Gather any excess cable length in the corner. Tighten all loose cable ties once the cable is routed in a manner that there is no risk of it being chafed or worn.

Applies to FWD

• Position the part as illustrated.

• Plug in the connector.

• Get a double cable tie from the kit and clamp down the cable to the heater in the junction between the resonator and pipe to the turbo.

Applies to all models

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

• Reinstall the wheel arch liners.

• Fold back the right fender liner's rear part.

• Refit the plastic nut holding the wheel arch liner to the body on the left and right side.

• Tighten the bolts in the front edge of the wheel arch liner on the left and right side.

• Reinstall the engine splash guard. Tighten.

• Reinstall the front right wheel. Tighten the wheel nuts to 140 Nm (103 lbf.ft.).