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

• Use the template from the installation instructions.

• Cut out following the dotted lines.

• Attach the template using tape edge to edge with the embossing to the front wing and the embossing in the bumper cover as illustrated.

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.

• 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.

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

• Remove the cover on the radiator expansion tank.

• Ensure that the front intake cover opens rearwards.

• Route the cable with ground lead from the front intake in front of 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.

• Disconnect the hose.

• Slacken off the screw to the AC compressor a few turns.

• Cut the hose from the oil cooler.

• Do not tighten the screw (K) fully yet.

• Turn the heater approximately as illustrated.

• Install the heater with bracket in the screw for the AC unit.

• Install the upper hose in the heater.

• Connect the hose from the oil cooler.

• Ensure that the heater is in the clamp properly and the hoses are routed correctly.

• Tighten all hose clips.

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

• Connect the cable to the heater.

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

Applies when fitting passenger compartment connector at the same time

• Take the locking sleeves and branching point from the kit.

• Connect the cables in accordance with the following:

Cable (1) from the engine block heater.

Cable (2) to the passenger compartment connector socket.

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

• Press the cables firmly into the branching point and press the locking sleeves in over the cable splices.

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

Applies when only the engine block heater is installed

• Connect the cables and clamp in clips.

Applies to all vehicles

• Clamp the cables at the sub-frame's front edge/upper edge.

• Clamp the cable splice at the existing cable harness.

Installation

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

• Post-fill the cooling system if necessary.

• Reinstall the detached components in reverse order.