Part 1

Auxiliary lights, installation kit

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

Auxiliary lights, installation kit

- Turn the ignition key to position 0.
- Disconnect the battery negative lead.

Note! Wait at least three minutes before unplugging the connectors or removing other electrical equipment.

Applies to cars without Bumper Bar

- Remove the number plate and holder.

- Apply the strips of tape as illustrated.
- Measure out the indicated measurements from the upper edge of the lower grille and remove the ends of the tape strips.

- Join both markings.

- Now mark the centre of the bumper cover with one edge of the strip of tape.

- Measure 200 mm (7 7/8 ") from the centre of the bumper cover and outwards and remove the long strips of tape on both side.

A
- Now drill in the markings on the sides using the appropriate drill bit - 8.5 mm (21/64") and L=240 mm (9 7/16") through the bumper cover (1), the impact absorption area (2) and the impact member (3). Predrill through the bumper cover using a smaller drill.

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

- Take a - 22 mm (7/8 ") hole saw and tape the centre drill to approx. - 8.5 mm (21/64 "). This is to get the hole saw to centre in the drilled hole.

- Open out the hole in the bumper cover (1) and the impact absorption area (2) on both sides using the hole saw - 22 mm (7/8").

Note! Do not drill through the impact member.

- Remove the tape strips.

Applies to cars with Bumper Bar

- Remove the number plate and holder.

- Apply the strips of tape as illustrated.
- Measure up the illustrated measurement from the Bumper Bar's top edge and remove the strips of tape on both ends.

- Join both markings.

- Now mark the centre of the bumper cover with one edge of the strip of tape.

- Measure 200 mm (7 7/8 ") from the centre of the bumper cover and outwards and remove the long strips of tape on both side.

A
- Drill in the markings using a drill bit - 8.5 mm (21/64") and L=240 mm (9 7/16") through the Bumper Bar (1), bumper cover (2), the impact absorption area (3) and the impact member (4). Predrill through the bumper cover using a smaller drill.

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

- Take a - 22 mm (7/8 ") hole saw and tape the centre drill to approximately - 8.5 mm (21/64 "). This is to get the hole saw to centre better in the drilled hole.

- Open out the hole in the Bumper Bar (1), bumper cover (2) and the impact absorption area (3) on both sides using the hole saw - 22 mm (7/8").

Note! Do not drill through the impact member.

- Remove the tape strips.

Applies to all cars without cooler to the turbocharger,

- Remove the eight screws in the air baffle.

- Remove the three clips by pressing together the fasteners and pulling them away.

- Remove the two screws for the lower air baffle on the front edge of the wheel housing on both sides.

- Loosen the air baffle so that the connectors on the inside of both sides can be removed.
- Remove the connectors with cable from the right-hand inside of the air baffle.

- Disconnect the cable harness and the washer hoses with clips from the air baffle's left-hand inside.
- Remove the air baffle.

Applies to cars without cooler to the turbocharger, without Bumper Bar

- Install the spacers.

- Install the two nuts from below.
Tightening torque: 24 Nm (17.7 lbf.ft.).

- Install the console.
- Install the screws.
- Install the number plate

Applies to cars without cooler to the turbocharger, with Bumper Bar

- Install the spacers.

- Install the two nuts from below. Tightening torque: 24 Nm (17.7 lbf.ft.).

- Install the spacers.
- Install the console.
- Install the screws.
- Install the number plate

Applies to all cars with cooler to the turbocharger,

- Fold back the wing liner.
- Loosen the connector and wiper hose to the headlight's high pressure washer.
- Place a container underneath to collect the washer water or seal the outlet on the washer pump.

- Fold back the wing liner.
- Loosen the connector on the inside of the air guide.

Hint: The following procedure should be performed by two people.

- Unhook the end of the bumper cover at the rear edge from the hooks on both sides (small picture). Carefully pull off the ends, they are secured by two clips on the front wing and three below the headlight.
- Pull loose the bumper cover forward in one piece.
- If the car is equipped with fog lamps, loosen the connectors to these.
- Remove the bumper cover.

- Install the two spacer screws in the impact member together with the two nuts on the rear.
- Tighten to a torque of 24 Nm (17.7 lbf.ft). Use a torque wrench, tighten from the front and counterhold the nuts at the rear.

Hint: The following procedure should be performed by two people.

- If the car is equipped with fog lamps, connect the connectors to these.
- Reinstall the bumper cover and make sure that all catches engage.

Applies to cars with cooler to the turbocharger, without Bumper Bar

- Install the console.
- Install the screws.
- Install the number plate

Applies to cars with cooler to the turbocharger, with Bumper Bar

- Install the spacers.
- Install the console.
- Install the screws.
- Install the number plate

Applies to all models

- Pull out the two lock pins from the right-hand headlamp.

- Pull out the headlamp some distance and detach the connector on the rear. Place the headlamp to one side.
- Repeat the operation on the other side.

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

- Undo the front ground screw inside the right-hand headlamp.
- Take out the new cable harness and connect the ground cable and tighten the bolt to 10 Nm (7.3 lbf.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.