Fuel-driven heater, D5244T

• 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.

• Fold the center seat cushion (1) forward. Fold the center backrest (2) forward by pulling the lever (3) toward you.

• Remove the center backrest. First pull the handle at the top of the reverse of the backrest. Then pull the backrest upwards.

• Fold the right-hand rear seat cushion forward.

• Fold the right-hand rear backrest forward.

• Remove the right-hand side cushion. First pull the top edge (1) towards you. Then lift the side cushion upwards (2).

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

• Fold the right rear backrest forward.
• Remove the seatbelt from the guide (1) on the right-hand side bolster.

• Remove the clip (1) at the side of the right-hand side cushion.
• Pull the top edge of the left-hand front cargo compartment panel out to access the upper catch for the side bolster.

• Remove the right-hand side cushion. First press in the catches (1) at the top edge of the reverse of the side cushion. Pull the cushion out slightly.
• Grasp the cushion using both hands. Twist the cushion clockwise until the catches on the inside release.
• Remove the side bolster. First pull out the top of the side bolster. Then pull upwards.

Applies to cars with mountings for Isofix on the right side of the rear seat

• 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 connector (1) and the screw (2) on the right backrest.
• Lift up the mounting (3) and pull out the backrest by at the same time rocking it back and forth to dislodge the pin from the mounting in the left-hand backrest.
• Remove the right 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) using a Ø4 mm (5/32") drill bit.

Примечание: Use an air 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 attachements of the fuel tank so that the tank is lowered a bit. This facilitates installation of the suction line for the fuel tank.

• 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

• Fold back the backrests, side cushions and seat cushions.
• Open the cover for the radiator expansion tank.

• 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. First insert 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. A total of six clips must be released.
• Pull down the fuel rail so that it hangs from the hoses.

• Take the fuel pump 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 from the kit. Secure the two fuel lines from the fuel pump to each other, opposite 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 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).

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

Illustration A

• 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.

Illustration B

• 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 pop rivets (1) in the left front wheel housing edge.

• Remove the two nuts (1) in the left wing liner (2).
• Fold the wing liner out of the way.

• Raise the car.
• Remove the screw (1) in the left air baffle (2) for the front brake.
• Remove the left-hand air baffle by pulling it rearward. Put it aside. It will not be reinstalled as it would be in the way of the heater.
• Remove the right-hand air baffle in the same way.

Примечание: This will be reinstalled later.

• Slacken the screws (1) and remove the air baffle (2) by pressing in the catches (3).
• Slacken the screws (4) and remove the engine splash guard (5).
• 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 subframe. Check that the fuel pipe does not rub against pipes or screw heads for the suspension.

• Reinstall the pipe elbow.
• Position the jack (1) under the front edge of the subframe.
• Take the weight off the subframe.
• Remove the screw (2) and the washer (3) from the 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 screw and nut 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 and clamp the fuel line of the heater at the ordinary fuel line.

• Remove the engine cover.

• Slacken the five screws in the brace between the MacPherson strut towers. Remove the brace.

• Detach the induction pipe from the air filter and front plate.

• Remove the cover from the air filter.

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

• Disconnect the connector and hose clamp on the air filter pipe.

• Remove the air filter by pulling it loose from its three attachment points. Move it up and position it so that the heater hoses can be routed. If necessary, detach additional cables to be able to move it aside.

Примечание: To facilitate removal: Use a socket extender and a 10 mm socket to press the attachment point catches together while pulling the air filter upward.

• Detach the quick-release coupling on the passenger compartment heater's left-hand heater hose (1) by pressing the two catches of the lock ring in opposite directions. Turn the quick-release coupling slightly and pull it out.
• Detach the heater hose from the radiator pipe on 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 and route them at the front edge of the transmission and then out to the front edge of the left wheel housing.
• Route the hoses rearward along the inside of the left-hand front member, across the transmission. Continue routing them up toward and along the rear of the turbocharger pipe.
• Use the quick-release coupling to connect the hose to the outlet in the firewall.
• Connect the other end of the hose to the radiator pipe (1) at the left rear edge of the cylinder head. Fasten it with a hose clamp from the kit. Make sure that the hoses do not come in contact with moving components or sharp edges in the engine compartment.

• Take the rubber-coated clamp and M8x16 screw from the kit. Clamp the heater hose from the firewall, tightening the clamp at the existing hole in the transmission end above the drive shaft.
• Torque tighten the screw to 24 Nm (18 lbf.ft.).

• 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.
• Reinstall the center air baffle and then the right-hand one.
• Reposition the fender liner and fasten the small plate with the two nuts.
• Rivet the front edge of the fender liner using the pop rivets from the kit.
• Lower the car slightly. Remount the wheel. Tighten to 140 Nm (103 lbf.ft.).

• Lower the car completely.
• Fill with coolant. Reinstall the expansion tank cap.
• Refit the air filter and reconnect any disconnected cables or hoses.
• Plug in the connectors of the air filter control module.
• Refit the cover over the air filter.
• Refit the brace between the MacPherson strut towers. Tighten the four M10 screws to 50 Nm (37 lbf.ft.) and the M12 screw to 80 Nm (59 lbf.ft.).
• 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.
• Software programming is done as described in the service information in VIDA.
• Test the function of the heater according to separate instructions.