Models with intercooler

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.

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. Connect top hose to radiator and tighten clip.
31. Connect expansion tank hose to radiator and tighten clip.
32. Fit bolt securing earth leads to bonnet platform.
33. Connect engine harness to main harness connector.
34. Secure glow plug relay to mounting bracket.
35. Connect multiplug to engine compartment fuse box.
36. Fit positive leads to fuse box and secure with screws.
37. Fit fuse box inner cover.
38. Fit fuse box cover.
39. Connect LH drive shaft to gearbox, as detailed in Differential oil seal. See MANUAL GEARBOX - ’PG1’, Repairs.
40. Connect RH drive shaft to gearbox. as detailed in RH Differential oil seal See MANUAL GEARBOX - ’PG1’, Repairs.
41. Fit front beam. See FRONT SUSPENSION, Repairs.
42. Fit through bolt securing engine steady bar to mounting bracket on engine and tighten to 85 Nm.
43. Connect selector rod to selector shaft and align holes.
44. Fit new roll pin securing selector rod to shaft and fit roll pin retaining clip.
45. Fit washers to gear change steady bar and connect steady bar to gearbox.