Models with intercooler

Models with intercooler

27. Connect harness multiplug to throttle potentiometer.

Models without intercooler

28. Connect throttle cable to abutment bracket and secure with nut.
29. Connect throttle cable to throttle lever.

All models

30. Remove caps from air conditioning pipes and compressor.
31. Clean mating faces of air conditioning pipe union and compressor.
32. Lubricate 2 new ’O’ rings with refrigerant oil and fit to compressor.
33. Position air conditioning pipe to compressor. Fit bolt and tighten to 35 Nm.
34. Clean condenser pipe to evaporator pipe union.
35. Lubricate new ’O’ ring with refrigerant oil and fit to compressor pipe.
36. Connect compressor pipe to evaporator pipe, fit bolt and tighten to 6 Nm.
37. Clean compressor pipe and condenser pipe unions.
38. Lubricate new ’O’ ring with refrigerant oil and fit to condenser pipe.
39. Connect compressor pipe to condenser pipe and tighten union to 45 Nm.

CAUTION: To prevent damage to air conditioning pipes and components, use two spanners when loosening or tightening union.

40. Connect top hose to radiator and tighten clip.
41. Connect expansion tank hose to radiator and tighten clip.
42. Fit bolt securing earth leads to bonnet platform.
43. Connect engine harness to main harness connector.
44. Secure glow plug relay to mounting bracket.
45. Connect multiplug to engine compartment fuse box.
46. Fit positive leads to fuse box and secure with screws.
47. Fit fuse box inner cover.
48. Fit fuse box cover.
49. Connect LH drive shaft to gearbox, as detailed in Differential oil seal. See MANUAL GEARBOX - ’PG1’, Repairs.
50. Connect RH drive shaft to gearbox. as detailed in RH Differential oil seal See MANUAL GEARBOX - ’PG1’, Repairs.
51. Fit front beam. See FRONT SUSPENSION, Repairs.
52. Fit through bolt securing engine steady bar to mounting bracket on engine and tighten to 85 Nm.
53. Connect selector rod to selector shaft and align holes.
54. Fit new roll pin securing selector rod to shaft and fit roll pin retaining clip.
55. Fit washers to gear change steady bar and connect steady bar to gearbox.
56. Fit bolt securing steady bar to gearbox and tighten to 10 Nm.
57. Fit exhaust front pipe. See MANIFOLD & EXHAUST SYSTEMS, Repairs.
58. Fit MAF sensor to air intake pipe and tighten clip.
59. Connect multiplug to MAF sensor.
60. Position earth lead to gearbox, fit bolt and tighten to 35 Nm.
61. Feed clutch cable through abutment bracket and connect to clutch release lever.
62. Position battery tray in vehicle.
63. Tighten 3 bolts securing battery tray to vehicle.
64. Position engine compartment fuse box to body, fit bolt and tighten to 10 Nm.
65. Fit 4 bolts securing battery tray to body and tighten to 10 Nm.
66. Fit and tighten bolt securing engine compartment fuse box to battery tray.