Part 2
Illustration A
- Remove the air baffle from underneath the bumper cover in order to allow access for inserting the cable between the left-hand side end face of the front grille and the seal in front of the radiator.
- Route the front engine block heater socket's cable through at the seal by the lower front grille's lefthand side end face. Route it above the radiator's left-hand bracket (1) and up to the lower edge of the side member. Clamp it by the bracket (1) using a tie strap from the kit. Route it along the lower edge of the front member and over the drive shaft. Route the cable up slightly in the engine compartment.
Illustration B
- Press the cable into the previously installed clips.
- Reinstall the air baffle in the bumper cover and to its rear mounting in the bracket, in the lower edge of the radiator.
- Reconnect the connectors for the fog lamps if applicable.
- Press the ends of the bumper cover into place on the body.
- Position the cable as illustrated, and clamp it in at the top of the strut using a tie strap from the kit. Route it up to the top of the engine compartment.
- Install three clips from the kit on the front edge of the panel above the windscreen wiper motor.
- Guide the cable up to the top of the engine compartment to the position illustrated.
Illustration A
- Press the front intake cable into the clips. Guide down the cable at point (1) and route down through the engine compartment (behind the AC pipes) down to the strut in the right link arm mounting.
Illustration B
- Clamp in the cable, from the top of the engine compartment and down, using a tie strap.
NOTE: The cable must not be clamped directly to AC, fuel or brake pipes.
- Clamp the cable from the front engine block heater socket in at the top of the strut using a tie strap from the kit.
- Grease O-ring on the front engine block heater socket's connector using low temperature grease (P/N 1161417-9).
NOTE: Do not get any grease on the surfaces of the connector.
Installing the engine block heater
- Remove the cover on the radiator expansion tank.
- Unscrew the drain nipple in the radiator pipe above the oil cooler in front of the right drive shaft. Drain the coolant.
- Detach the hose clips of the left oil cooler hose and remove the hose.
- Put the hose to the side.
- 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.
NOTE: The screws are self-tapping so it may be slow inserting them. Make sure that the screws are centered straight into the holes, so that the screw heads are flat against the bracket.
- Take the heater, rubber-clad clamp and bolt from the kit. Fasten the heater with the clamp. The connections should point straight back.
- Take the long hose and two hose clips from the kit. Connect the hose between the radiator pipe and upper heater socket.
- Tighten the hose clips.
- Take the remaining hose and two hose clamps from the kit. Connect the hose between the oil cooler and the lower outlet on the heater. The end with the long straight section must be connected to the oil cooler.
- Tighten the hose clips.
- Take the radiation shield from the kit and thread on the joint cable of the heater.
- Connect the short electrical cable (which was routed earlier) to the engine block heater. Press it firmly into the engine block heater connection.
- Press in a locking sleeve from the kit over the cable splice.
- Pull the radiation shield up so that it fully covers the connector on the heater.
- Take the grey tie strap kit and clamp the radiation shield by the heater in the upper edge.
Illustration A applies to cars without turbocharger
On cars with petrol engine without turbo, route the cable with radiation shield below the power steering hoses/pipes.
- Fit a double tie strap to the two steering gear pipes and the cable with radiation shield.
- Fit the double tie strap over the hoses' press sleeves.
Illustration B applies to cars with turbocharger
On cars with petrol engine and turbo, route the cable with radiation shield under the power steering hoses/pipes and under the turbo pipe.
- Fit a double tie strap to turbocharger pipe and the cable with radiation shield.
- Fit a double tie strap to the cable and the left power steering pipe.
- Reinstall the left-hand wing liner. Tighten the wing liner to the left-hand side member.
- Tighten the two wing liners to the bumper cover on the right and lefthand sides.
- Refit the covers to the nozzles for the headlamp high-pressure washers.
- Fill with coolant, run the engine to operating temperature, bleed the cooling system and check that there are no leaks.
- Reinstall the engine splash guard.
- Remount the front wheel and tighten the wheel bolts to 90 Nm (66 lbf.ft.).