Models with air conditioning fitted

14. Clean mating faces of camshaft carrier and camshaft cover.
15. Ensure bolt holes in camshaft carrier are clean and dry.
16. Fit new gasket, dry, to camshaft cover.

17. Fit camshaft cover.
18. Fit camshaft cover bolts and working in the sequence shown, tighten to 12 Nm.
19. Connect glow plug feed lead to No.2 glow plug, fit and tighten nut.
20. Remove plugs from FIP and injectors.
21. Position injector pipes and connect unions to FIP and injectors, tighten unions to 28 Nm.

CAUTION: To prevent damage to fuel system pipes or components use 2 spanners when tightening unions.

22. Connect spill return pipes to injectors, tighten unions to 10 Nm.
23. Connect injector needle lift sensor multiplug to harness and secure to bracket on injection pump.
24. Connect radiator top hose to coolant outlet elbow and tighten clip.
25. Align dipstick tube bracket to coolant outlet elbow, fit bolt and tighten to 25 Nm.
26. Connect engine coolant temperature gauge sensor Lucar to harness.
27. Connect multiplug to ECT sensor.

Models with air conditioning fitted

28. Position alternator top mounting bracket to coolant outlet elbow, fit bolts and tighten to 25 Nm.
29. Fit bolt securing alternator to mounting bracket and tighten to 25 Nm.

All models

30. Connect hose to brake servo vacuum pipe and secure with clip.
31. Align brake servo vacuum pipe to coolant outlet elbow, fit bolt and tighten to 25 Nm.
32. Fit bolt securing vacuum pipe to camshaft cover and tighten to 10 Nm.
33. Position FIP timing belt backplate and bracket to cylinder head, fit bolts and tighten to 8 Nm.
34. Clean tensioner pulley.
35. Fit tensioner pulley to locating dowel, fit Allen bolt but do not tighten.
36. Position camshaft timing belt back cover to cylinder head and block, fit bolts and tighten to 8 Nm.
37. Align engine harness to back cover and secure with clips.
38. Clean camshaft gear and mating face.
39. Locate camshaft gear on camshaft.
40. Fit new camshaft gear retaining bolt but do not tighten at this stage.

CAUTION: Ensure camshaft does not rotate.

NOTE: Bolt is tightened after timing belt has been tensioned. Do not fit timing belt at this stage.

41. Clean FIP timing belt drive gear and mating face.
42. Locate FIP timing belt drive gear on camshaft.
43. Fit new FIP timing belt drive gear retaining bolt but do not tighten at this stage.

CAUTION: Ensure camshaft does not rotate.

NOTE: Bolt is tightened after FIP timing belt has been tensioned. Do not fit timing belt at this stage.