Auxiliary Lights, Installation Kit (2004-2009)

• Turn the ignition key to position 0.
• Disconnect the battery negative lead.
  NOTE:

  Wait at least five minutes before disassembling the connectors or removing other electrical equipment.

• Remove the number plate.
• Remove the number plate cradle.

Illustration applies to cars up to and including model year -2007 

• Take the bracket for auxiliary lights from the kit. Install the bracket in the holes that the number plate cradle was in. Use the bracket's upper  holes.

Illustration applies to cars from and including model year 2008- 

• Take the bracket for auxiliary lights from the kit. Install the bracket in the holes that the number plate cradle was in. Use the bracket's lower  holes.

• Pre-drill the two holes using a 8 mm (5/16")  drill bit in the center of the brackets upper hole (1). Hold the drill straight and drill to the member inside.
• Remove the bracket for auxiliary lights.
• Drill out the holes using a 13 mm (1/2")  drill bit through the bumper cover and the expanded polystyrene layer to the member inside.
• Remove any shavings from the hole and smooth off the hole edges.

Removing the front bumper cover 

• Remove the three screws securing the air baffle to the lower edge of the bumper cover.

• Remove the clips by pressing down the center of the clips and pull them straight up.
• Remove the two screws (1).

• Remove the five screws on each side.

• Remove the cover for the washer nozzle.

  HINT: Carefully grip the cover. Pull the cover out until the catch becomes accessible from the underneath. 

• Press the catch up. Remove the cover. Do not damage the painted surfaces and washer nozzles.

• Detach the ends of the bumper cover on the left and right-hand sides. Grasp the end of the bumper cover inside the wing liner. Carefully pull the end of the bumper cover so that the five catches at the rear edge and under the lights release. Lift off the bumper cover
• Lift off the bumper cover.
• Disconnect the connectors for the fog lamps, if installed.

• Remove the foam member by carefully pulling it straight out.
• Remove the screws (1) holding the horn completely and place them to one side. They will not be reused.
• Install the inner bracket and horn as illustrated and secure using the screws from the kit. Tighten to 10 Nm (7.5 lbf. ft.)  .

• Reinstall the foam member and insert the corners of the bracket in the pre-drilled holes.
• secure the foam member in the applicable holes in the bumper rail inside. If it is a tight fit, the holes can be drilled out slightly to facilitate access.

• Take the cable harness for the auxiliary lights. Cut off the plastic clip that holds the two loose separate cable harnesses.
• Insert the cable for the auxiliary lights from the engine compartment and out along the grille. Measure with the cable so that you pull out the required length.
• Raise the bumper cover towards the car and hold it away from the car slightly.
• Pull out the end of the cable for the auxiliary lights through the other hole, seen from the right.

• Reinstall the bumper by following the instructions in steps 5-9 in reverse order.
• Route the cable through the other hole from the right in the grille.
• Secure the bracket in the inner bracket's protruding horn with the screws and the washers from the kit but do not tighten them too hard yet. The washers must be between the horn and bracket.

• Pull the longer of the two cable ends to the right-hand mounting of the auxiliary lights bracket.
• Position the cable harness at the upper edge of the auxiliary lights bracket and secure by it using four cable ties (1) from the kit.
• Check that the screws for the number plate cradle are opposite the holes.
• Tighten the M8 screws. Tighten to 18 Nm (13.3 lbf. ft.)  .
• Install the number plate cradle and tighten the screws.

Connecting auxiliary lights 

• The kit contains flat pin connectors and plastic isolators that must be used to isolate the + cable.
  CAUTION:

  Read through the supplied installation instructions for your auxiliary lights. In most cases the wiring must be routed into the light housing, through a rubber grommet, before securing the flat pin connectors.

Cable routing and electrical connection: 

• Route the cable with fuse and terminals up to the fuse box. Route the cable so that it is hidden and in such a way that it cannot be damaged.

• Secure the cable harness at the existing cable harness from the radiator and up to the fuse box using two cable ties from the kit.
  NOTE:

  Ensure that the cable harness does not come into contact with sharp edges and is not at risk of being damaged.

• Remove the cover for the fuse box by releasing the catches at the rear edge and then by pulling it up at the rear edge.

• Make a cut-out in the rubber seal, large enough to route the cable for the power connection in the fuse box.

• Pull in the fuse holder with fuse, as well as the red cable with cable terminal in the fuse box.
• Place the red cable in the cut-out in the rubber grommet and position the fuse holder with fuse on top of the existing cables as far to the left as possible in the fuse box.
• Connect the red cable to terminal 15 in the fuse box.

• Take a cable tie from the kit and secure the fuse holder with fuse at the existing cables.
• Connect the pre-routed ground lead (1) to the exiting ground terminal (2).
• Tighten the ground screw. Tighten to 10 Nm (7.5 lbf. ft.)  .

• Route the cable further under the insulation and panels on the cowl panel so that it is protected
• Secure the cable with clamps from the kit.

• Clamp the cable at the top edge of the cowl panel.

• Detach the plastic panel on the left-hand side of the cowl panel, seen from the front, by unscrewing the two plastic nuts and then placing to one side.

• Open the glove compartment.
• Use a plastic weatherstrip tool to pry loose the panel. The panel is secured by two clips on each short side.
• Pull the panel away downwards.

• Remove the panel on the right-hand end of the dashboard by carefully prying it off using a plastic weatherstrip tool all the way around until the three clips release. Do not damage the dashboard.

• Remove the clip holding the nozzle for the air duct on the right-hand side.

• Remove the five screws in the opening of the glove compartment.

• Remove the glove compartment front section by pulling it back until the two clips in the upper edge release, and disconnecting the two connectors on the upper side.

• Remove the screw to the air vent on the right-hand side. Pull it away to the right and put it to one side.

• Remove the three screws for the inner section of the glove compartment.
• Pull out the glove compartment and place to one side.

• Remove the soundproofing panel on the right-hand side by first pressing in the center of the clips and then pulling the panel away with the clips.

• Disconnect the connector (1) marked roof 1 by pressing in the catches and pulling straight up.

• Move the catch holding the pin in the connector by pressing it to the side using a small screwdriver and pull the catch forward.
• Take the short cable harness from the kit. Connect the two pins of different sizes in the connector.
• Connect the green cable with the smaller pin in terminal 8 (1) and the black cable with larger pin in terminal 9 (2). The pins cannot be installed incorrectly as the pins are of different sizes.
• Press in the pins until they click into place.
• Press the catches that hold the pins back into place and reinstall the connector in the distribution box.

• Fold the insulation mat to the side where it covers the rubber grommet.
• Make a hole in the rubber grommet using a pointed object at the side of the thick wiring in the middle. Use expansion pliers to enlarge the hole.
• Route a piece of wire or similar through the hole and out to the engine compartment.
• Secure the two cable ends at the wire using tape and route into the passenger compartment.

• Pull the cable from the rubber grommet. Lubricate with normal soap if it is difficult to route through.
• Take the cable that has been routed into the passenger compartment. Connect the two flat pin connectors (1) to the available terminals (2) in the connector recently connected with the other cable.
  NOTE:

  The cables from the engine compartment can be connected in any of the two outer terminals.

• Take the relay from the kit and press into the connector.

• Secure the relay by the existing cable harness above the rubber grommet using a cable tie from the kit.

• Detach the panel behind the center console by grasping it by the sides and pulling straight down.

• Mark out a rectangle on the panel, as illustrated, for installing the auxiliary lights switch.
• Drill four 8mm (5/16")  holes in the corners of the marked out rectangle.
• Saw/cut out the hole according to the markings. File or cut-out the corners so they become smooth.
• Smooth down the hole edges.
• Take the switch surround from the kit. Try pressing it into the hole.
• File to create more space if necessary.

• Take the switch from the kit and press it into the surround so that the hooks engage properly.
• Press the surround in the panel so that the hooks click into position.
• Reinstall the panel loosely to access the switch's connector.

• Route the wiring with the two-pin connector so that it is hidden under the panels and reaches the switch.
• Connect the connector to the switch's corresponding connector.
• Reinstall the panel completely.

• Reinstall all components removed from around the glove compartment by following steps 24-31 in reverse order.