| | Installing the front intake, applies to the S40/V50, MY -07 |
| | J8601099 |
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| | Installing the front intake, applies to the S40/V50, MY -07 |
| | J8601100 |
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| | J8601101 |
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| | 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.
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| | J8601102 |
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| | 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.
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| | J8000359 |
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| | J8601130 |
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| | J8601131 |
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| | J8601087 |
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| | J8601084 |
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| | J8903376 |
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| | Illustration A Illustration B |
| | J8601086 |
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| | 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.
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| | J2900319 |
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| | 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.
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| | J2900320 |
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| | J2900321 |
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| | Illustration A Illustration B |
| | Installing the front intake, applies to the S40/V50, MY 07- |
| | J8000359 |
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| | Installing the front intake, applies to the S40/V50, MY 07- |
| | J8601130 |
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| | IMG-265763 |
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| | J8601087 |
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| | J8601084 |
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| | J8903376 |
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| | J8601086 |
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| | 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.
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| | IMG-265778 |
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| | 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.
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| | IMG-265779 |
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| | 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.
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| | IMG-265781 |
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| | IMG-265782 |
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| | Installing the front intake, applies to the C30 |
| | IMG-247823 |
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| | Installing the front intake, applies to the C30 |
| | IMG-248765 |
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| | IMG-249205 |
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| | IMG-247824 |
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| | Illustration A Illustration B |
| | IMG-247825 |
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| | 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.
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| | J8000359 |
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| | IMG-247826 |
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| | J8601131 |
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| | J8601087 |
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| | J8601084 |
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| | J8903376 |
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| | Illustration A Illustration B |
| | IMG-248768 |
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| | IMG-247843 |
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| | Illustration A 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.
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| | IMG-247844 |
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| | 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.
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| | IMG-247845 |
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| | IMG-247846 |
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| | Illustration A Illustration B |
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| | IMG-332918 |
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| | Installing the front intake, only applies to the C30 2010- |
| | IMG-331946 |
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| | IMG-331947 |
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| | IMG-331948 |
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| | IMG-332920 |
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| | IMG-331989 |
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| | IMG-331990 |
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| | Illustrations A and B Take a new panel, front intake cable with washer and nut from the kit.
Note!
The washer must be positioned as illustrated. |
Route the cable and ground lead through to the engine heater. Ensure the connector is turned so that the cover's sides are parallel with the plates in the panel and that the cover opens from the panel's left-hand side (Image B). Tighten the connector.
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| | IMG-331991 |
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| | J2900313 |
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| | IMG-360291 |
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| | 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 cable for the front engine block heater socket from the front edge of cover for the control module, along the underside of the front member and over the drive shaft. Press the cable into the previously installed clips.
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| | J2900477 |
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| | J2900297 |
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| | J2900298 |
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| | Drill a Ø 4 mm (5/32 ”) hole for the ground lead, on the outside of the left-hand front member, approximately as illustrated. Remove any swarf. Treat the edges of the holes using a rust-proofing agent.
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| | J2900299 |
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| | Installing the engine block heater |
| | J2900406 |
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| | Installing the engine block heater |
| | J2900461 |
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| | J8704179 |
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| | J8704183 |
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| | Illustration A Illustration B |
| | J8704146 |
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| | Remove the plug in the engine block, under the left-hand side of the manifold, use a Hex socket, part no. 9512965.
Note!
There is a small amount of coolant remaining in the engine. |
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| | J8704147 |
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| | Take the heater from the kit and brush sealing paste, part no.1161056, on the threads. Tighten the heater in the hole in the engine block, use wrench. part no.9997158. Angle it so that it engages in the transmission's mounting flange on the engine.
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| | D3601932 |
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| | J8704148 |
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| | 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.
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| | J8704185 |
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| | Take the heat deflector hose from the kit and cut it to a length of 200 mm (7 7/8"). Thread the heat deflector hose onto the cable right up to the heater, so that it covers the whole connector on the heater. Take the grey tie strap (1) from the kit and clamp the heat deflector sleeve at the upper edge.
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| | J8704170 |
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| | Pull the cable (1) from the engine block heater, over the gearbox and on to the drive shaft where the front socket cable (2) is located. Press in a clamp (3) from the kit at the edge on the bracket for the gear selector cables. Press the cable into the clamp.
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| | J2900302 |
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| | 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.
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| | J2900296 |
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| | 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 socket Position (3) cable from the front engine block heater socket.
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| | J2900303 |
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| | 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), part no. 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.
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| | J2900304 |
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| | 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.
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| | J2900470 |
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| | Connect the short cable from the kit to the engine block heater, to the routed cable (1) from the front socket. (When fitting junction connector/timer relay at the same time, the cable from the front socket is connected to the single outlet on the junction connector/timer relay instead. Refer to the installation instructions for passenger compartment socket/timer relay). Firmly press the cable junction together.
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| | J2900418 |
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| | J2900419 |
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| | Refit the heat deflector plate and torque tighten the screws to 10 Nm (7 lbf. ft.). 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. Refit the covers to the nozzles for the headlamp high-pressure washers.
Bleeding and filling the cooling system Illustration A Illustration B Illustration C |
| | Reinstall the engine splash guard. Reinstall the front wheel and tighten the wheel nuts to: Step 1: 20 Nm (15 lbf.ft.) Step 2: 110 Nm (81 lbf.ft.)
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