Installation Kit, Auxiliary Lights

Installation kit, auxiliary lights





































INTRODUCTION
- NOTE! Read through the whole installation instruction before starting the work.
- The illustrations display the procedure in order of operation. The order of operation is repeated in the text section






Installation kit, auxiliary lights

Installing the bracket

Note! This accessory requires software unique to the car.




- Switch off the ignition and remove the key.
- Open the bonnet and remove the battery box cover.
- Disconnect the battery negative lead.




- Remove the number plate and holder.




- Locate the two markings that are situated 82 mm (3 1/4") under the top edge of the outer cover. Make holes in the markings with a scriber.




- Screw the bracket into the top holes using new screws from the kit.




- Mark the centre of the rectangular holes.




- Drill into the markings with the designated drill bit.

Note! It is important that the holes are drill horizontally to the car.




- Drill through the outer cover (1), the shock absorbing section (2) and the impact member (3).




- Remove the bracket.
- Drill out the holes using a 22 mm 7/8" hole saw through the outer cover and the shock absorbing section.

Note! Do not drill through the impact member.




- Remove the screws.





Remove:
- the clips by pinching the catches and then pulling them out
- the cover panel.





Install:
- the spacers
- the bracket
- the screws.




- Install two nuts from below, tightening torque: 24 Nm (17.7 lb.ft.)
- Reinstall the number plate.

Cable routing




- Remove the headlamp's lock tab on the right and left-hand sides.




- Remove the headlamp on the right and left-hand sides.




- In order to facilitate cable routing, tape the red cable (1) together with the longer auxiliary lights' cables (2), black and blue. Finally, tape the end of the shorter auxiliary lights' cables (3).




- Undo the front ground screw inside the right-hand headlamp.
- Connect the ground lead and tighten the screw to 10 Nm (7.3 lb.ft).




- Install the relay on the cable harness.
- Secure the relay and socket onto the car's existing cable harness using two tie straps.




- Route the cable harness under the front plate.




- Secure the cable harness branching point at the rear edge of the front plate using butyl tape.




- Secure the cable harness using butyl tape.




- Route the cables taped together from below,
- black and blue, out through the grille (1),
- red cable, out at the left-hand headlamp (2).

Applies to cars with intercooler (turbo)
- Route the cables using a wire or string.




- Secure the cable harness with a tie strap.




The illustration shows an outline of the connection of the auxiliary lights. See the separate instructions for the complete method.
- Thread the cables through the lamp housing.
- Install cable terminals onto both cables.
- Fit a socket housing to the blue (BL) cable to avoid short circuits.
- Connect the blue (BL) cable to the lamp's cable.
- Connect the black (SB) cable to ground on the light insert.




- Route the cable harness to the fuse holder. Secure the cable harness using butyl tape.




- Remove the cover from the fuse box.




- Remove the cover.




- Undo the nut (1).
- Press in the catches and lift the relay holder up.




- Release all catches and lift the fuse/relay holders up at the same time.




- Cut off the rubber teat.




- Thread the cable harness through the rubber grommet.




- Turn the left-hand fuse holder over. Install the red (RD) cable in position 28.




- Reinstall the detached components in reverse order.

Note! Check that guides and rubber seals are fitted correctly, and that the cables do not become trapped.

- Reinstall the nut (1), tightening torque: 10 Nm (7.3 lb.ft).




- Install the fuse in position 28.
- Reinstall the cover.




- Remove the end face panel on the right-hand side.




- Remove the centre sill trim panel by first carefully prizing it off at the front edge and pulling it up until the three clips release. Following which, pull it away forwards.




- Detach the sealing strip. Only detach by the front sill trim panel.




- Remove the front sill trim panel by first pulling it up at the rear edge until the clip there releases. Pull it backwards further until the clip in the centre releases. Following which, pull it diagonally downwards from the A-pillar panel.




- Remove the screws and the panel.




- Unplug the connector for the lighting.




- Remove the two screws.




- Remove the seven screws.
- Cut off the tie strap for the glovebox lighting on the rear side.
- Pull the glovebox out slightly and unplug the grey connector on the rear side.
- Remove the glovebox.




- Move the carpeting aside. Make a cut in the thick insulating mat starting level with the blue connector of the central electronic module (CEM) and then continue straight down.
- Move aside the insulating mat to access the grommet.




- Route the green (GN) cable backwards and down to the rubber grommet.




- Raise the car and remove the engine splash guard.




- Remove the existing rubber grommet.




- Cut off a small rubber teat on the new rubber grommet and thread through the cable. Route the cable into the passenger compartment.
- Install the rubber grommet.
- Reinstall the engine splash guard and the cover panel.




- Unplug the green connector on the Central Electronic Module (CEM).




- Remove the connector's cover by lifting the four hooks.




- Lift at the four hooks and remove the catch.




- Connect the green (GN) cable to position 7.

Reinstall:
- the catch
- the cover
- the connector.
- Fold back the carpet.





Installing the glovebox
- Reinstall the glovebox and torque tighten the M6 screws to 10 Nm (7.5 lb.ft).
- Plug in the connector on the rear side of the glovebox and fit a new tie strap to the cable.
- Install the screws in the lower edge.
- Reinstall the cover panel with lighting and screws.




- Connect the battery negative lead.
- Reinstall the battery box cover.

Illustrations A and B




- Reinstall the headlamps.






Reinstall:
- the front sill trim panel
- the sealing strip
- the rear sill trim panel
- the end face panel.





Applies to cars with automatic gearbox
- Move the gear selector to position D.




- Press the panel in at the front edge.
- Lift the panel at the rear edge and remove it.




- Remove the cover.




- Install the new switch. It must be fitted in the first available button location seen from the steering wheel.

Note! Cover plugs are purchased separately.

- Reinstall the gear selector panel.




- Program the software as required. Programming and Relearning