Models with air conditioning fitted (page 2 of 6)

44. Clean mating faces of inlet manifold, exhaust manifold and cylinder head.
45. Fit new manifold gasket to cylinder head.
46. Manoeuvre inlet and exhaust manifolds into position on cylinder head.

47. Fit nuts, bolts and washers securing manifolds to cylinder head.
48. Working in the sequence illustrated, tighten nuts to 25 Nm and bolts to 33 Nm.
49. Fit 2 bolts securing exhaust manifold to support bracket and tighten to 25 Nm.
50. Fit new gasket to turbocharger oil drain pipe. Align pipe to turbocharger, fit bolts and tighten to 8 Nm.
51. Clean turbocharger oil feed pipe union and banjo bolt.
52. Fit new sealing washers to banjo bolt. connect oil feed pipe to turbocharger and tighten banjo bolt to 18 Nm.
53. Connect vacuum pipe to EGR valve.
54. Connect vacuum pipe to turbocharger actuator.
55. Connect exhaust front pipe to manifold. See MANIFOLD & EXHAUST SYSTEMS, Repairs.
56. Position air intake pipe and connect to turbocharger, tighten clip.
57. Connect multiplug to MAF sensor.
58. Connect breather hose to camshaft cover and tighten clip.

59. Align camshaft gear timing mark with mark on back cover.
60. Insert timing pin 18G 1523 through hole in gearbox adapter plate. Hold pin in contact with flywheel and using assistance, carefully rotate crankshaft clockwise until timing pin can be felt to enter hole in flywheel.

CAUTION: Do not rotate crankshaft too far, pistons may contact the valves.

61. Remove crankshaft pulley bolt.