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

• Undo the clamp for the intake hose and pull the hose off.

• Use isopropanol to clean the bumper shell where the cutting template for the front engine block heater socket 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.

• 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.

• Drill a Ø4 mm (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.

• Pull the intake hose down and secure it at the sub frame.

• Take a spacer sleeve from the kit and tighten in the right-hand hole on the front side of the engine above the joint between the engine block and oil sump.

• Take the heater and clamp from the kit and assemble as illustrated.

• Take screws from the kit and tighten the heater in the spacer sleeve.

• Cut the hose (1) as follows:

Measure out for cutting the coolant hose between the oil cooler and the thermostat housing.

Position the hose at the heater's lower connection, ensure that it runs around the oil filter properly and cut it.

• Smooth off the hose ends if necessary. Do not cut off too much of the hoses.

• Take hose clamps and tighten the hoses to the heater, preferably from underneath.

• Clamp the cable in the hole for the purpose in the left front mounting in the sub-frame.

• Take the clip with cable tie for a Ø 6.5 mm (Ø1/4 ") hole and press it into the left hole on the inside of the upper edge of the subframe.

• Take the clip from the kit and press onto the sub frame's upper/front edge and at the left front-edge of it.

• Lubricate the O-ring on the connector on the cable from the front engine block heater socket with low temperature grease.

Applies when only the engine block heater is installed

If the passenger compartment connector socket is to be installed at the same time then install the junction connector now in accordance with illustration C and D, and connect the cables to it.

• Take the joint cable to the engine block heater from the kit and connect to the cable from the front engine block heater socket. Press the connectors together firmly and secure a locking sleeve from the kit over the cable 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 passenger compartment connector is to be installed at the same time, install the junction connector now. Lubricate the O-rings on the contacts as previously.

• Connect:

cable (1) from the front intake

cable (2) to the passenger compartment connector socket

cable (3) to the heater

• Insert the junction connector into the space in the sub frame. Tighten the junction connector with the cable tie around the outer connector of the two on the junction connector. The position of the edge clip at the upper edge of the sub frame's left-hand side may need adjusting in order to fit the junction connector.

Applies to all vehicles

• Lubricate the O-ring on the connector on the jointing cable with low temperature grease.

• Firmly secure the cable into the heater's connector.

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

• Move the intake hose up into place and tighten the clamp. Ensure that it ends up on the correct side of the cable to the heater.

• Clamp the cable splice around the intake hose using a double cable tie and edge clips with cable tie on the inside of the upper edge of the sub frame.

Installation

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

• Top up the cooling system as required.