Passenger compartment heater, Flexifuel

• Turn the ignition switch to position 0.

Примечание: Wait at least three minutes before unplugging the connectors or removing other electrical equipment.

• Remove the tunnel console's right side panel by carefully pulling it away starting at the rear edge. It is secured with five clips on the inside.

• Fold aside both the carpet and the insulation panel. Uncover the right side of the tunnel console's front section and the hole for the rubber bushing in the firewall.

• Undo the front screw in the mounting for the centre console.
• Take the bracket for the passenger compartment socket from the kit. Tighten it with the previously removed screw.
• Position it so that it is straight and torque tighten the screw to 24 Nm (18 lbf.ft.).

• Fold the carpet back toward the bracket.
• Take a scriber and pierce a hole in the carpet opposite the two holes in the bracket.

• Take the passenger compartment socket, a locking sleeve, and two screws from the kit. Install the passenger compartment socket on the bracket.

• Press in the locking sleeve on the passenger compartment socket. Slide the locking sleeve as far as possible on the connection for the passenger compartment socket.
• Take a carpet knife and cut a slit in the carpet just in front of the locking sleeve. Make the cut as long as the diameter of the locking sleeve.
• Remove the passenger compartment connector socket from the bracket and fold the carpet to one side.

Примечание: Do not damage any wiring and hoses under the carpet.

• Unscrew the screws and remove the engine splash guard.

• Remove the rubber seal in the firewall. It is not going to be used again. The rubber seal is partially hidden behind the heat shield.

• Cut off the grey strip clamp on the heat shield by the heater.
• Pull back the heat shield to access the connectors' locking sleeve.

• Carefully pry up the four catches on the lock sleeve with a small screwdriver and pull it backwards.
• Unplug the connector from the heater's socket.
• Carefully cut loose the locking sleeve from the cable. New locking sleeve is found in the kit.

• Cut off the strip clamp and loosen the clip for the cable from the flange in the engine block.
• Remove the heat shield from the cable, it is going to be used again.

Illustrations A and B

• Pull up the cable and route it on the back of the drive axle's heat shield.

• Get the branching connector, holder, screw, washer, and nut from the kit. Assemble and tighten down.

• Grease the O-ring on the connector for the front socket and both connectors on the branching connector using low temperature grease (part no. 1161427).

Примечание: Do not get any grease on the surfaces of the connector.

• Get the two splicing cables and the small locking sleeves from the kit.
• Press the cables into the branching connector.
• Press the locking sleeves over the joints.

Примечание: Make sure that the branching connector faces so that the shorter cable is in the front position.

• Get a hose clamp from the kit and tighten down the branching connector on the steering gear in the position as shown.
• Press the cable from the front socket securely in the branching connector and press a locking sleeve from the kit over the joint.

• Get strip clamp with clips from the kit, press into holes in transmission, and tighten down the cable with the strip clamp.

• Turn the heater's connector so that it faces the rear.

• Route the shorter cable to the heater on top of the turbo pipe.
• Get the old heat shield and fit the cable to the heater.

• Grease the O-ring on the connector for the splicing cable to the heater with low temperature grease (part no.1161427).

Примечание: Do not get any grease on the surfaces of the connector.

• Press the splicing cable's connector into the socket on the heater.
• Press a locking sleeve from the kit over the connector.

• Pull over the heat shield so that it fully covers the heater's connector.
• Get a grey strip clamp from the kit and tighten down the heat shield to the heater's connector.

• Get a double strip clamp from the kit, and clamp down the cable with heat shield for the engine heater by the turbo pipe.

• Get the heat shield from the kit and fit the cable to the passenger compartment connector.
• Fit it on all the way to the branching connector.

• Get the rubber bushing from the kit and cut the top of the big rubber piece.

• Lubricate the rubber bushing with low temperature in order to make it easier to install the cable and rubber bushing in the hole in the firewall.
• Thread the rubber grommet onto the cable.
• Adjust the length of the cable to the rubber bushing's placement in the firewall's hole.

Примечание: Do not get any grease on the surfaces of the connector.

• Route the remaining cable (to the passenger compartment connector) from the branching connector to the right end of the power steering.
• Press on a double clamp from the kit on the front pipe and fasten the cable.

• Press the rubber bushing into place.

Illustration A

• Route the cable onto the bracket for the passenger compartment connector socket.
• Route the cable from the engine compartment through the hole in the carpet.

Illustration B

• Route the cable from the engine compartment through the hole in the carpet.
• Grease the O-ring with low temperature grease (part no. 1161427).
• Connect the cable to the passenger compartment connector socket. Press a locking sleeve (from the kit) over the joint.
• Fold the carpet back into position and install the passenger compartment connector using both the screws.

Примечание: Ensure that no grease gets onto the connector surfaces.