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

• Wipe dry.

• Cut out the template according to the dotted lines.

• Secure the template edge-to edge with the line at the front edge of the wing and lower edge of the bumper shell.

• 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.

Applies to R-design

• 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 tape to ensure the location of the part.

• 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.

Applies to all vehicles

• 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.

Illustrations A and B

• Install the attaching brace and nut from the kit.

• Rotate the connector for the front engine block heater socket carefully so that the cover opens backwards (Illustration B).

• 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.

Illustrations A and B

• Route the cable with the ground cable from the front engine block heater socket behind the left-hand front mounting for the subframe and down on the inside of the subframe.

• Drill a Ø 4mm (Ø 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. Tighten the ground cable.

• Clamp the cable in the hole in the subframe's front mounting.

• Drain the coolant.

• Tighten the nipple after use.

• Take two clips from the kit and install them on the upper edge of the subframe, turned in toward the subframe U-profile. Install the clips in the positions illustrated.

• Detach the double clamp on the cable to the alternator that is located on the thermostat housing hose.

• Rotate the catch on the thermostat housing pipe anticlockwise. Detach the hose and drain the remaining coolant.

• Cut off the hose using a sharp knife in accordance with the measurements. Make the incision as straight as possible. The short hose-end that was cut off shall be used again.

• Cut out the short cut-off hose section as illustrated.

• Discard the cut-off hose bend.

• Remove the short hose-end and press it on the pipe that runs to the thermostat housing. Make sure that the cut-out in the hose connection is turned down and fits into the corresponding pin in the pipe connection.

• Rotate the catch on the pipe clockwise against the stop.

• Take a hose clamp from the kit and install it on the hose-end.

• Take the engine block heater, bracket, rubber coated clamp and screw from the kit and assemble them as illustrated.

• Do not tighten the screw yet.

• Take the hose clamp from the kit and fit it onto the engine block heater's upper connection.

• Position the engine block heater with bracket in the front edge of the oil sump and connect both hose-ends to the engine block heater's connections.

• Take a screw from the kit and tighten the bracket with engine block heater into the existing hole in the oil sump.

• Now adjust the engine block heater in the rubber coated clamp so that the hoses are properly fitted on the engine block heater's connection.

• Tighten the screw to the rubber coated clamp.

• Tighten the hose clamps to the engine block heater.

• Install the double clamp to the cable for the alternator in the engine block heater's upper hose.

• Lubricate the O-ring on the connector for the heater's cable with low temperature grease P/N 1161427.

• Connect the cable from the front engine block heater socket to the engine block heater and press it in firmly.

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

• Take a double tie strap and clamp the joint cable into the pipe that runs to the thermostat housing.

Applies when fitting passenger compartment connector at the same time

• Take the locking sleeves from the kit.

• Connect the cables in accordance with the following:

  Cable (1) from the engine block heater.

  Cable (2) joint cable to the passenger compartment connector socket.

  Cable (3) from the front engine block heater socket.

• Press the cables firmly into the junction connector and press the locking sleeves in over the cable splices.

• Firmly press together the cable from the engine block heater and the cable from the front engine block heater socket and press in a locking sleeve from the kit over the cable splice.

• Press the cable into the two clips and tighten the cable splice to the existing cable harness.

• Fill with coolant, run the engine to operating temperature, bleed the cooling system and check that there are no leaks.

• Top up the cooling system as required.