Models with intercooler (page 3 of 3)

69. Remove through bolt securing RH steady bar to engine mounting bracket.
70. Remove 3 bolts securing mounting bracket to engine.
71. Remove nut securing mounting bracket to engine mounting.
72. Loosen 2 nuts securing restraint bar to body.
73. Remove engine mounting bracket.

74. Remove through bolt securing engine LH mounting to bracket on body.
75. Remove 2 bolts securing engine mounting to bracket on gearbox.
76. Remove engine mounting.
77. Using assistance, manoeuvre and lower engine and gearbox from vehicle.
78. Disconnect hoist from adjustable lifting bracket.
79. Remove engine and gearbox from beneath vehicle.

Refit

1. Using assistance, position engine and gearbox beneath vehicle.
2. Connect hoist to adjustable lifting bracket tool 18G 1598.
3. Raise and manoeuvre engine and gearbox into position in vehicle.
4. Adjust lifting bracket tool so engine is horizontal in engine compartment.
5. Position engine LH mounting to gearbox mounting bracket, fit bolts and tighten to 100 Nm.
6. Align engine LH mounting to bracket on body, fit through bolt and tighten to 85 Nm.
7. Fit mounting bracket to engine RH mounting.
8. Align mounting bracket to engine, fit 3 bolts and tighten to 100 Nm.
9. Fit nut securing mounting bracket to engine mounting and tighten to 85 Nm.
10. Tighten nuts, engine mounting restraint bar to body, to 45 Nm.
11. Connect steady bar to engine mounting bracket, fit through bolt and tighten to 80 Nm.
12. Lower hoist and disconnect adjustable lifting bracket tool 18G 1598.
13. Connect hose to fuel return pipe and secure with clip.
14. Connect hose to fuel filter and secure with clip.
15. Connect 3 engine harness multiplugs to main harness.
16. Secure multiplugs to bracket on bulkhead.
17. Remove plugs from PAS pipes and hoses.
18. Connect PAS pump feed hose to fluid reservoir and secure with clip.
19. Fit new ’O’ ring to PAS intermediate pipe.
20. Connect PAS pump pressure hose to intermediate pipe and tighten union to 20 Nm.

CAUTION: To prevent damage to components, use two spanners when loosening or tightening unions.

21. Remove container positioned to collect fluid loss from PAS system.
22. Connect coolant hose to heater valve and tighten clip.
23. Connect hose to coolant rail and tighten clip.
24. Connect vacuum pipe to EGR valve.
25. Connect multiplug to EGR solenoid.
26. Connect brake servo vacuum hose to vacuum pipe and secure with clip.