Fuel-driven heater (B6324S, B6324S5)

• Turn the ignition switch to position 0.
• Disconnect the battery negative lead.

Примечание: Wait at least five minutes before disconnecting the connectors or removing other electrical equipment.

Applies to cars with two rows of seats

• Remove the front floor hatch by first lifting it up a bit and then pulling it out of the mountings in the front edge.

Applies to cars with two rows of seats

• Lift out the front storage box.

Примечание: Removal of the right-hand seat in the second row (steps 4-9) applies to all cars. For cars with three rows of seats, the left-hand seat and center seat of the second row must also be removed. See step 10.

• Remove the panel on the right rear mounting on the right-hand front seat. Prise up the rear edge of the panel slightly and then pull rearwards and upwards.

• Slide the seats of the first row as far forward as possible.
• Carefully prise loose and remove the panel over the joint between the door sills on the right side.

• Remove the panel for the right front seat mounting of the second row's right-hand seat by pressing down the catch (1) on top and pulling the panel forward. Remove the screw underneath.

• Remove the panel for the front seat mountings of the second row's right-hand seat/center seat by pressing down the catches (1) on top and pulling the panel forward. Remove the screw for the right-hand seat.

• Lower the backrest of the right-hand seat in the second row.
• Remove the cover (1) of the rear seat mountings of the right-hand seat by prising the rear edge loose. Remove the screws.

• Undo the sill panel of the right rear door. Pull the rear edge until the clips release. Continue forward until the remaining clips release.
• Unhook the sill trim panel from the B-post panel. Place the sill trim panel in the cargo compartment.
• Remove the seat.

Осторожно: Exercise care when lifting the seats out of the passenger compartment so the mountings do not damage the door panels.

Applies to cars with three rows of seats

• Remove the corresponding panels and screws on the left-hand side and for the left-hand and center seat of the second row following steps 4-9.
• Remove the left-hand and center seat.

Осторожно: Exercise care when lifting the seats out of the passenger compartment so the mountings do not damage the door panels.

Applies to cars with three rows of seats

• Remove the air nozzles on the right and left-hand side.

Illustration A applies to cars with two rows of seats

• Bend aside the floor mat and secure it with the seat belt on the left-hand side.
• Carefully bend aside the styrofoam insulation to provide access to the cover of the tank unit.

Осторожно: Take care. The styrofoam insulation comes off easily.

Illustration B applies to cars with three rows of seats

• Bend aside the floor mat and the insulating mat.
• Use a screwdriver or the like to hold the mat in place.
• Remove the air duct.
• Remove both panels of styrofoam insulation.

• Remove the four screws in the tank fitting cover.
• Carefully prise loose the cover using a weatherstrip tool.

• Remove the four screws (1) from the front and rear mountings of the fuel tank so that the tank is lowered a bit in order to fit a suction line to the fuel tank. If necessary, loosen and unscrew the fuel filter screw (2) to lower the fuel tank even more.

• Drill the connection (1) in the tank fitting with a Ø4 mm (5/32") drill bit.

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

• Insert the pipe (1) from the kit down into the connection (2). Press the pipe down until it is flush with the connection.
• Take the fuel line with electrical line from the kit. Affix protective tape on the end of the fuel line that is to be inserted through the hole in the floor (the one with the short, unconnected line end).
• Insert the whole line 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.

Applies to cars with two rows of seats

• Carefully bend up the end of the styrofoam insulation.

• Place a spacer underneath.

Applies to all models

• Route the line previously routed together with the fuel line under the seat frame and connect it to the front connector (1) in the contact bridge (2).
• Applies to cars with two rows of seats: Remove the spacer and fold down the styrofoam insulation.
• Place the line in the holder in the tank unit cover.
• Refit the tank fitting cover and secure with the four screws.

• Refit the styrofoam insulation panels.
• Applies to cars with three rows of seats: Refit the air duct.
• Fold back the carpet.
• Applies to cars with three rows of seats: Refit the air nozzles under the outer seats.
• Reinstall the seats.

Осторожно: Exercise care when lifting the seats into the passenger compartment so the mountings do not damage the door panels.

• Secure the seats, tightening the screws to 48 Nm (35 lbf.ft.).
• Refit the panels and the covers over the seat mountings.
• Refit the panels over the joints between the door sills.

Applies to cars with two rows of seats

• Refit the front storage box.
• Refit the front floor hatch.

• Route the fuel hose with wiring harness (1) forward in the rear edge of the fuel tank. Route it along the fuel tank's right side and forward. Let it hang down.

• Undo the rail for the fuel line by inserting a small screwdriver in the little hole between the rail and the yellow clip. Move the clip in the same direction as the oblong hole in the rail. The rear black clip has a little spot on the clip where you position the screwdriver and move it forward.

• Take the fuel pump with line from the kit. Insert the line in the front edge of the fuel tank's right side.
• Route the fuel line so that is next to the existing fuel line in the cut-out on top of the fuel tank. Then position the fuel line 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 with bracket and place the bracket on the top of the fuel tank mounting bracket in front of the small holes for the blind rivets.
• Use two metal pop rivets (2) from the kit to rivet the fuel pump bracket at the fuel tank mounting bracket.

• Use a double clamp from the kit to clamp the two fuel lines from the fuel pump to each other at the two blue markings on the fuel lines.
• Press the brake pipe back into the clamp.
• Tighten the four screws that hold the tank in place. Tighten the screw of the fuel filter if this was loosened. Tighten the screws 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).

• Use a double clamp from the kit to clamp the fuel line at the fuel pipe at point (1).

• 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.

• Remove the left front wheel.
• Drill out the five pop rivets (1) holding the fender liner in place and the pop rivet (2) in the bottom edge of the bumper. Use a Ø6 mm (1/4") drill bit.

Remove:

• any rivet residue
• the plastic nuts (3) holding the fender liner in place
• the small protective plate.

Applies to cars with the accessory side decor

• Примечание: > Do not undo the side decor of the front fender.

Bend aside only the retaining lugs on the side decor of the front fender so that the edge of the fender liner can be released.

Applies to cars without the accessory side decor

• Undo the fender extension by carefully prising loose the lower corner using a weatherstrip tool.
• Pull it loose up to the highest point of the wheel housing until the three catches in the lower edge and the two clips a little higher up have released.

• Remove the left bumper panel by carefully prising it loose in the left bottom edge until the clips on the bottom and inside release. Continue pulling until the clips all around release.

• Bend aside the fender liner and secure it with a tie strap or the like.

• Remove the protective engine plate (1) by removing the screws (2).

• Remove the front skid plate by first removing the six screws (1) on the bottom.
• With the aid of a helper, pull the skid plate forward. Pull one corner until one of the skid plate retaining lugs releases from the sub-frame. Then undo the other corner. At the same time, it may be necessary to carefully bend down the bottom edge of the bumper lining.
• Open the cap of the radiator expansion tank.
• Thread a hose onto the engine coolant drain nipple.
• Open the drain nipple. Drain off the coolant.

• Remove the two screws from the lower rear torque rod and remove it.

• Remove the two screws of the torque rod mounting in the subframe and remove the mounting.

• Detach the fuel return hose from the clamp at the rear edge on the right inside part of the subframe.
• Remove the clamp. There is a new double clamp in the kit.

• Take the fuel pipe with the three pre-fitted clips (1) from the kit and install it on the subframe.
• Press the fuel pipe with clips into the front edge of the subframe. The pipe is a tight fit. You will need to twist and turn it somewhat to get it into place.
• Check that the fuel pipe does not catch on the subframe. Check that the fuel pipe does not rub against pipes or screw heads for the suspension.

• Remove the existing fuel return hose from the clamp.
• Press the newly routed fuel pipe into the bottom of the clamp and then press the return hose into place.

Illustrations A and B

• Take the short fuel pipe from the kit and (from the front) insert it under the steering gear and anti-roll bar and back toward the previously routed fuel line at the right rear mounting of the subframe. It is a tight fit. It may be necessary to twist and turn the pipe to get it into place.
• Thread a hose clamp onto the short hose end on the front pipe.
• Insert the front edge of the pipe in the rubber hose onto the front pipe. Fasten with the hose clamp.
• Press the fuel pipe with double clamp into the hose in the subframe.
• Press the fuel return hose in the other aperture in the double clamp.

Illustrations A and B

• Fit a new clamp (1) on the hose end of the previously routed fuel line at the subframe's right rear mounting-
• Attach the hose end to the short pipe and tighten the clamp.
• Clamp the fuel hose at the fuel return hose using the double clamp (2).
• Clamp the fuel fuel at the fuel return hose using the tie strap (3)

• Refit the lower torque rod mounting. Tighten the screws to 80 Nm (59 lbf.ft.).

• Refit the lower torque rod. Tighten the screws to 80 Nm (59 lbf.ft.).

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

• Fit the heater (1) on the bracket (2) with the screws (3) from the kit and tighten.

• Raise the heater into its installation position.
• Take a small hose clamp for the fuel line from the kit. Install the clamp on the fuel hose (1) from the fuel pipe on the subframe.
• Press the fuel line on the inlet (2) on the fuel pump (FP). Tighten.

• Take a new screw (1) from the kit and secure the heater to the left front corner of the sub-frame. Do not tighten hard yet.
• Take the metal bracket and two nuts from the kit.
• Position one of the metal bracket's retaining lugs on the stud (2) of the heater and fit the nut. Tighten loosely.
• Position the other retaining lug of the bracket on the stud (3) and fit the nut.
• Tighten the heater to the sub-frame and bracket. Tighten the screw (1) to 105 Nm (78 lbf.ft.). Angle tighten to 120° or max. 280 Nm (206 lbf.ft.)
• Remove the protective cap from the pre-routed connector (4). Press in the catch on the top and pull it off.
• Connect the cable from the heater to the connector.

Remove:

• the two screws
• the air filter and put it aside.

• Remove the protective cover over the control module.

• Press in the catches on the connectors of the air filter control module, turn the handles and remove the connectors.

• Unplug the connector and remove the hose clamp from the air filter pipe.

• Undo the plastic nut (1) on the air filter's left-hand bracket and pull the air filter from the front member.
• Unplug any remaining connectors or hoses. Put the air filter aside.

• Remove the quick-release fitting on the passenger compartment heater's left-hand heater hose (1) by pressing the two catches of the lock ring in opposite directions. Twist the quick-release fitting slightly and pull it out.
• Detach the heater hose on the radiator pipe at the left rear edge of the cylinder head.
• Remove the heater hose. It will not be used again.

• Take the heater hoses from the kit. Route them down in the front edge of the transmission and though to the front edge of the left-hand wheel housing.
• Route the hoses back along the inside of the left front member and over the transmission. Continue routing them up toward the firewall.
• Using the quick-release fitting, connect the hose to the outlet in the firewall.
• Connect the other hose end to the radiator pipe (1) at the left rear edge of the cylinder head. Secure it with a hose clamp from the kit. Make sure that the hoses do not come into contact with moving parts or sharp edges in the engine compartment.

• Take the holder and screw for the heater hoses from the kit. Fasten the holder at the AC compressor bracket. Tighten the screw to 24 Nm (18 lbf.ft.).

• Place the heater hoses and power steering hose in their respective holders.

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

• Tighten the drain nipple on the radiator. Remove the hose.
• Refit the front skid plate and tighten to 50 Nm (37 lbf.ft.)
• Reposition the fender liner. Refit and tighten the small plate and plastic nuts.
• Press the fender extension into place.
• Use the pop rivets from the kit to rivet the front/lower edge of the fender liner into place.
• Refit the bumper panel.
• Remount the wheel and tighten the bolts to 140 Nm (103 lbf.ft.)

• Fill with coolant. Reinstall the expansion tank cap.
• Refit the air filter and reconnect disconnected cables and hoses.
• Reinstall the air filter in the fender liner using the plastic nut.
• Refit the induction pipe on the front plate between the headlamps. Tighten the screws to 10 Nm (7 lbf.ft.)
• Plug in the connectors of the air filter connector.
• Refit the cover over the air filter.
• Reconnect the battery negative lead
• Start the engine and bleed the cooling system. Check for leaks.
• Reinstall the engine splash guard and tighten the screws to 25 Nm (18 lbf.ft.)
• Reinstall the engine cover.
• Programme the software in accordance with the service information in VIDA.
• Test the function of the heater according to separate instructions.