Models fitted with air conditioning

Refit

1. With assistance, raise and position engine and gearbox in vehicle.
2. Fit LH engine mounting to body and tighten bolts to 45 Nm.
3. Align LH engine mounting to bracket on body and fit but do not tighten through bolt at this stage.
4. Fit RH engine mounting bracket to engine and tighten bolts to 120 Nm.
5. Lower engine onto RH engine mounting, fit PAS hose support bracket to stud and tighten nut to 80 Nm.
6. Lower chains to release weight of engine onto mountings and tighten LH mounting through bolt to 80 Nm.
7. Align upper tie rod to RH engine mounting. Fit bolt securing tie rod to mounting and bolt securing tie rod to body. Tighten both bolts to 80 Nm.
8. Fit LH engine mounting support strut.
9. Tighten bolt securing strut to starter motor to 80 Nm.and bolt securing strut to LH engine mounting to 60 Nm.
10. Ensure PAS pipe union is clean.
11. Fit NEW ’O’ ring to PAS pipe and tighten union to 22Nm.
12. Connect PAS fluid hose to reservoir and secure with clip.
13. Align PAS fluid pipes to bracket on RH engine mounting, fit clamp and secure with nut and bolt.

Models fitted with air conditioning

14. Align A/C pipe clip to PAS pipe bracket and secure with screw.

All models.

15. Fit clutch slave cylinder to bracket, ensure push rod is engaged with lever and fit clip to secure cylinder to bracket.
16. Connect fuel cooler hose to FIP and secure hose with clip.
17. Connect fuel cooler hose to fuel rail and secure hose with clip.
18. Connect fuel return hose to fuel rail.
19. Connect fuel feed hose to fuel rail and secure hose with clip.
20. Connect outlet hose to expansion tank and secure with clip.
21. Connect hoses to heater matrix and secure with clips.
22. Connect top hose to radiator and secure with clip.
23. Connect vacuum pipe to EGR valve.
24. Connect brake servo hose to pipe at camshaft cover and secure hose with clip.
25. Connect pressure sensing hose to turbo charger and secure hose with clip.
26. Connect multiplug to EGR modulator valve.
27. Connect multiplug to MAP sensor.
28. Connect engine harness multiplug to bracket on LH wing valance.
29. Connect engine harness multiplugs to main harness.
30. Connect engine harness multiplugs to main harness.
31. Connect multiplug to earth lead header.
32. Connect positive leads to fuse box and and tighten screws to 2.75 Nm.
33. Fit cover to fuse box.
34. Connect engine harness multiplug to fuse box.
35. Fit battery carrier. See ELECTRICAL, Repairs.