Fuel driven heater 912-B, 6 cylinder engines

• Remove the rear seat cushion (1) by pulling it up at the front and then forwards.

• Remove the seat belt from the guide (1) on the right-hand side cushion
• Insert a hand down the side of the lower section of the right side cushion
• Release the catches. At the same time lift the side cushion
• Place the cushion to one side
• Fold the backrest forward.

Applies to cars with Isofix mountings

• Remove the screws (1). Slacken off the end mounting (2) for the seat belt
• Remove the nut (3) and the washer (4) from the stud
• Remove the mounting (5).

Applies to the right-hand side

• Disconnect the cable (1) and the screw (2) on the backrest
• Lift up the mounting (3) and pull out the backrest by twisting it backwards and forwards to remove the pin from the mounting in the left backrest.

• Push the insulation panel to one side so that the cover (1) is accessible
• Remove the nuts (2) and the cover
• Drill out the connection (3) in the fuel tank unit (4). Use a 4 mm (5/32") diameter drill bit.

Примечание: Use a compressed air power drill with a greased bit.

Illustration A displays the front mounting

Illustration B displays the rear mounting

• Remove the four screws (1) in the front and rear mountings so that the fuel tank lowers slightly. This allows the suction pipe for the fuel tank to be installed. If necessary, remove the screw (2) for the fuel filter to lower the fuel tank further.

• Insert the pipe (1) (from the kit) into the connection (2). Press the pipe down until it is in contact with the connection
• Take the fuel line with the power cable from the kit. Apply tape on the end on the section of the fuel line which is to be inserted through the hole in the floor. (The one with a short free cable end.)
• Insert the whole cable assembly (3) between the floor and the fuel tank out to the right.

• Press the quick-release connector (1) onto the connection until a click is heard. Check that the quick-release connector is secure
• Connect the power cable, routed with the fuel line to the connector (2) in the connector bridge (3).

• Position the wiring in the rubber grommet in the cover. Reinstall the cover. Tighten the cover using the four nuts.

Applies to cars with Isofix mountings

• Reinstall the Isofix mounting and seat belt buckle
• Tighten the screw. Tighten to 40 Nm (30 lbf.ft.).Tighten the nut. Tighten to 30 Nm (22 lbf.ft.).

Applies to all models

• Reinstall the backrests, side cushions and seat cushions.

• Route the fuel hose with the cable harness (1) at the rear edge of the fuel tank. Route along the right-hand side of the fuel tank and allow the hose to hang.

• Detach the fuel rail (1) by inserting a small screwdriver into the small hole between the yellow clip and the fuel rail. Push the clip in the direction of the arrow. Repeat this for the other clips. There are six clips to disconnect
• Pull down the fuel rail so that it hangs from the hoses.

• Take the fuel pump (FP) and cable from the kit. Insert the cable up at the front edge on the right-hand side of the fuel tank
• Route the cable so that is next to the existing cable in the cut-out on top of the fuel tank. Then position the cable on the right-hand side of the wiring which runs to the engine compartment
• Pull up the wiring so that the fuel pump (FP) is positioned as approximately as illustrated.

• Remove the brake pipe (1) from the clamp
• Take the fuel pump (FP) and bracket. Position the bracket on top of the bracket for the fuel tank mounting, opposite the small holes for the rivets
• Take two metal rivets (2) from the kit. Rivet the fuel pump (FP) bracket at the bracket for the fuel tank mounting.

• Take the double clamp (1) from the kit. Secure the two fuel lines from the fuel pump (FP) to each other, opposite the two blue markings on the fuel lines
• Press the brake pipe back into the clamp
• Tighten the four screws holding the fuel tank. Also tighten the screw for the fuel filter if slackened off. Tighten the screws. Tighten to 24 Nm (18 lbf.ft)
• Connect the connector (1) from the pre-routed power cable to the fuel pump (FP)
• Connect the quick-release connector (2) on the pre-routed fuel line to the fuel pump (FP).

• Secure the fuel line in the brake pipe at point (1) using a double clamp from the kit.

• Press into place the fuel hose from the recently installed fuel pump (FP). Press into place in the bottom of the rail and forwards, in the cut-out furthest to the right.

Примечание: The marking on the fuel hose must be opposite the point where the fuel hose goes into the rail
- Slide back the retaining clip for the rail. Press the rail against the car body. Ensure that the rail is securely installed.

• Raise the car slightly
• Remove the left front wheel
• Raise the car a little more
• Drill out the five rivets (1) in the edge of the front left wheel housing.

• Remove the two nuts (1) in the left wheel arch lining (2)
• Bend the wheel arch lining out of the way
• Open the expansion tank cap.

• Raise the car
• Remove the screw (1) from the left air baffle (2) for the front brake
• Remove the left-hand air baffle by pulling it backwards. Place the air baffle to one side. It will not be reused as it obstructs the heater
• Remove the right air baffle in the same way. (It will be reinstalled later).

• Remove the screws (1). Remove the air baffle (2)
• Remove the screws (3). Remove the splash guard (4)
• Thread a hose onto the engine coolant drain nipple
• Open the drain nipple. Drain off the coolant.

• Pull off and push the pipe elbow to one side so that the fuel pipe can be positioned.

• Remove the power steering pipes and the plastic hose from their clips to make installing the fuel pipe easier. In order to push the upper power steering pipe to one side, the rubber coated clamp on the upper side of the front edge of the sub-frame may need to be removed.

• Install the fuel pipe using the four pre-installed clips (1) (from the kit) on the sub-frame. Insert the fuel pipe between the disconnected pipes and the sub-frame. Press the fuel pipe into place using the clips in the front edge of the sub-frame and in the bottom in the clips (2) that secured the plastic hose. On older car models, there are two free clips for the fuel line below the existing pipes on the inside on the sub-frame. Due to limited space, the fuel pipe needs to be worked slightly in order to position it.

• Reinstall the power steering pipes. Press the plastic hose into place on the outside of the fuel pipe. On older models, the plastic hose is reinstalled in its clips. Reinstall the rubber coated clamp if this has been removed
• Check that the fuel pipe does not catch on the sub-frame. Check that the fuel pipe does not rub against pipes or screw heads for the suspension.

• Reinstall the pipe elbow
• Install the mobile jack (1) under the front edge of the sub-frame
• Take the weight off the sub-frame
• Remove the screw (2) and the washer (3) from the front left mounting on the sub-frame.

• Install the heater (1) on the bracket (2.) Use the screws (3) from the kit. Tighten the screws.

• Position the heater for installation
• Take a small hose clamp (from the kit) for the fuel line. Install the clamp on the fuel hose (1) from the fuel pipe on the sub-frame
• Press the fuel line on the inlet (2) on the fuel pump (FP). Tighten.

• Position the bracket (1) (from the kit) on the screw (2) protruding in the wheel arch
• Take a nut from the kit. Finger tighten
• Install the heater and the bracket (3) in the left front mounting on the sub-frame. Use the screw (4) from the kit. Finger tighten
• Turn the bracket (1) so that its hole is aligned with the screw underneath the hole in the bottom of the bracket (5)
• Secure both brackets using nuts from the kit. Finger tighten
• Check that the heater does not catch on any surrounding components
• Tighten the heater to the sub-frame and the brackets
• Tighten the screw (4). Tighten to 105 Nm (78 lbf.ft). Angle-tighten 120° or MAX 280 Nm (206 lbf.ft.)
• Remove the protective cover from the pre-routed connector (6). Press in the catches on the top of the connector to release the cover
• Connect the cable from the heater to the connector
• Remove the jack.

• Take the join cover and the short fuel line from the kit. Install the cover on the pipe.

• Insert the end of the fuel line, which is kinked in two places, under the power steering and the anti-roll bar, on top of the rear right corner on the sub-frame.

• Take a hose clamp from the kit. Thread the hose clamp onto the short fuel line on the fuel pipe on the sub-frame
• Connect the short fuel pipe to the fuel line. Slide the pipe into the fuel line. Slide the pipe in so far that the two pipes are in contact with each other. This prevents air pockets from forming
• Squeeze the hose clamp together.

Illustration A

• Take a tie strap from the kit. Clamp the protective tube at the fuel pipe so that it is securely installed.

Illustration B

• Take a hose clamp from the kit. Thread the hose clamp onto the fuel line up to the fuel pump (FP) that was routed previously
• Connect the fuel line to the short fuel pipe. Slide the pipe into the fuel line. Slide the pipe in so far that the two pipes are in contact with each other. This prevents air pockets from forming
• Ensure that the fuel line is routed correctly and does not obstruct the plastic hose or rub against the sub-frame or other components
• Squeeze the hose clamp together.

Примечание: Fuel lines and fuel pipes must be at least 15 mm (19/32") from brake pipes.

• Take a tie strap from the kit and clamp the fuel pipe at the plastic hose.

• Take a double clamp from the kit. Clamp the fuel line for the heater into place at the normal fuel line.

• Lower the car slightly
• Remove the intake hose (1) between the air intake and the air cleaner.

• Fully disconnect the hose clamp (1)
• Remove the vacuum valve with hoses and the cable (2) from the mounting on the reverse of the air cleaner (ACL), at the right-hand lower edge, and move the valve away from the gearbox.

• Release the air cleaner (ACL) from its three catches. There is one catch on the rear edge of the air cleaner (ACL), one on the front edge and one on the left-hand side. Lift up the air cleaner (ACL). Use a small socket with an extension bar to compress the four catches. Pull off the air cleaner (ACL)
• Pull off the air cleaner (ACL) from the pipe for the turbocharger (TC). Position the air cleaner (ACL) on top of the front edge of the engine to expose the gearbox.

• Remove the two screws for the spring strut stay on the left-hand side to access the quick-release connector in the cowl panel.

• Pull the spring strut stay up on the left-hand side. Position a shim between the mounting and the spring strut turret.

• Disconnect the quick-release connector on the left heating hose (1) for the passenger compartment heater. Twist the catch in the direction of the arrow (the catch is stamped with an arrow head). Twist the connector slightly. Pull out the connector
• Disconnect the heater hose (2) on the left-hand side of the cylinder head
• Remove the heater hose.

• Thread the two heater hoses from the kit down along the front mounting of the sub-frame
• Route the hoses over the gearbox as illustrated. Connect the hose (1) to the left-hand side of the cylinder head using a hose clamp. Tighten the hose clamp. Connect the hose (2) to the left-hand hose connector in the cowl panel.

• Connect the two heater hoses (1) to the heater using the hose clamps from the kit. Tighten the hoses.

• Tighten the drain nipple on the radiator. Remove the hose
• Reinstall the splash guard. Tighten to 25 Nm (18 lbf.ft.)
• Reinstall the centre air baffle and then the right-hand one
• Fold the wheel arch lining back into position. Tighten the wheel arch lining using the two nuts
• Rivet the front edge of the wheel arch lining using the pop rivets from the kit
• Lower the car slightly. Reinstall the wheel. Tighten to 140 Nm (103 lbf.ft.).

• Open the cover on the fuse holder in the engine compartment
• Install a 25A fuse in terminal 1
• Reinstall the cover
• Then tighten the left-hand mounting for the spring strut stay. Tighten the screws. Tighten to 50 Nm (837 lbf.ft.).

• Lower the car completely
• Fill with coolant. Reinstall the expansion tank cap
• Reinstall the air cleaner and connections
• Start the engine. Bleed the radiator system
• Program the software using VCT2000 according to the service information in VIDA
• Test the function of the heater according to separate instructions.