Work Procedure

Section A - Check electric coolant pump function





- Turn ignition key to ON position (engine not running)

- Open hood and check if the electric coolant pump is running and coolant is flowing into the coolant bottle.

- If pump is active and coolant is flowing, no further work is required, close hood and turn ignition to OFF position.

- If pump is not running and there is no coolant flowing into the coolant bottle, proceed to Section B below.

Section B - Wire installation

- Record radio preset stations

- Turn ignition switch to off position

- Remove battery cover, disconnect battery ground (GND) cable and battery positive (+) cable and move aside.





- Loosen and remove 2 screws -1- and remove cover -A- from behind left headlight.

- Unsnap fuse box -B- from battery side cover, pull up and tie off.

- Remove bolt -2-, unsnap battery side cover at both rear corners, pull up and remove battery side cover.

- Loosen and remove battery hold- down bolt -3- with clamp and remove battery from the vehicle.





- Remove bolts -4- holding cable guide to battery tray and bolt -5- to air cleaner.





- Remove bolts -6- and remove battery tray from the vehicle.





- Disconnect wire harness connector -7- from coolant fan control module -8- which is located under the left side member below the battery tray.

- Unclip harness retaining clip -9-.





- Slide the locking clip -C- on the connector to unlock pins.

- Using a 1 mm diameter wire push the white plug out of position # 1 of the connector.





- Open harness holder by unsnapping covers -D-.

- Insent new wire, ZVW 971 228,(taped end) into connector -7- and slide locking clip into position.

- Route wire (dotted line) along harness and into harness holder.

- Tape (completely cover) new wire to existing harness from the plug to the harness holder using electrical tape ZVW 601100.





- Under the air intake tube, lift harness connector -E- up and roll it out of the holder.

- Disconnect connector and remove the right angle harness cover -F- from the connector.





- Unlock the pins in the connector by sliding connector towards the flat side of the hard shell.

- Using a small wire (1 mm diameter) push the white plug out of position # 13.

- Carefully slit the tape -H- covering the corrugated harness cover by using the open edge of cover as a guide.

- Insert other end of new, ZVW 971 228, (untapped end) into connector position # 13 and slide connector to lock pins in position.

- Route wire (dotted line) under corrugated harness cover to larger corrugated harness cover and into harness holder.

- Re-tape end of corrugated wire covers -H- using electrical tape.

NOTE:
Excess wire length can be looped in harness holder.

- Close harness holder by snapping covers closed.

- Reinstall right angle harness connector cover to connector.

- Reconnect connector and roll into holder under the air intake tube.

- Reconnect connector to coolant fan control module under left side member and clip harness retainer together.

WARNING:
Ensure that there is no person inside the vehicle when connecting the battery.

- Temporarily connect battery positive (+) and ground (GND) to battery, using jumper cables.

- Turn ignition key to ON position (engine not running).

- Under the hood, listen for electric coolant pump running and look for coolant flowing into coolant bottle.

- If coolant pump is not running, check harness connectors for correct wire pin position and placement.

- If coolant pump runs, turn ignition "OFF", disconnect battery ground (GND) and positive (+) cables.





- Reinstall battery tray, using 4 bolts -6- and torque 8 Nm (71 in/lbs)





- Reinstall bolt -5- to air cleaner and bolts -4- from cable guide to battery tray.

- Reinstall battery and battery clamp

- Reinstall battery side cover and secure with 1 bolt

- Reconnect battery positive (+) and ground (GND) to battery

- Reinstall fuse box on top of battery

- Reinstall battery cover on top of battery

- Reset clock, window pinch protection and radio preset stations

- Set readiness code