All Models (page 5 of 5)

Refit

1. Connect hoist to adjustable lifting bracket tool 18G 1598.
2. Using assistance, raise engine and manoeuvre into position in vehicle.
3. Adjust lifting bracket tool so engine is horizontal in engine compartment.
4. Fit LH engine mounting to body and tighten bolts to 45 Nm.
5. Fit mounting bracket to gearbox and tighten bolts to 60 Nm.
6. Raise unit to align LH mounting to bracket on gearbox and tighten bolts to 45 Nm.
7. Fit engine mounting bracket to mounting, fit special washer and start but do not tighten nut.
8. Align engine to mounting bracket and engage dowels.
9. Fit bolts securing mounting bracket to engine and tighten to 105 Nm.
10. Fit nut securing bracket to engine mounting and tighten to 80 Nm.
11. Fit tie bar to RH engine mounting and align to body.
12. Fit through bolts securing tie bar to body and engine mounting, DO NOT tighten bolts.
13. Lower hoist and disconnect adjustable lifting bracket tool 18G 1598 from engine lifting bracket.
14. Fit fuel filter into its bracket.
15. Align lower steady bar to bracket on engine.
16. Fit bolt steady bar to bracket on engine tighten both steady bar bolts to 80 Nm.
17. Connect selector rod to selector shaft and align holes.
18. Fit new roll pin securing selector rod to shaft and fit roll pin retaining clip.
19. Fit washers to gear change steady bar and connect steady bar to gearbox.
20. Fit bolt securing steady bar to gearbox and tighten to 10 Nm.
21. Connect LH drive shaft to gearbox, as detailed in LH differential oil seal. See MANUAL GEARBOX - ’PG1’, Repairs.
22. Connect RH drive shaft to gearbox, as detailed in RH differential oil seal. See MANUAL GEARBOX - ’PG1’, Repairs.
23. Align PAS reservoir to body and secure with bolts.
24. Connect PAS pump feed hose to reservoir and secure hose with clip.
25. Clean PAS high pressure pipe connections at bulkhead.
26. Lubricate new ’O’ ring with PAS fluid and fit to male connection.
27. Connect PAS high pressure union at bulkhead and tighten.

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

28. Connect vacuum pipe to EGR valve.
29. Connect brake servo vacuum hose to pipe at camshaft cover and secure with clip.
30. Connect coolant hose to heater valve and secure hose with clip.
31. Connect top hose to radiator and tighten hose clip.
32. Connect heater hose to coolant rail and tighten hose clip.
33. Connect fuel feed and return hoses to pipes and secure hoses with clips.
34. Connect battery negative lead to starter solenoid and secure with nut.
35. Position harness to engine and secure clips at coolant rail.
36. Connect multiplug to vehicle speed sensor.
37. Connect multiplug to CKP sensor.
38. Position earth leads to gearbox, fit bolt and tighten to 35 Nm.
39. Connect Lucar to starter solenoid.
40. Connect reverse lamp switch leads to harness.
41. Connect multiplug(s) to FIP.
42. Secure harness clip to bracket on FIP.
43. Connect multiplug to alternator.
44. Connect lead to alternator terminal, fit and tighten nut and reposition terminal cover.
45. Connect multiplugs to cooling fan.
46. Connect injector lift sensor multiplug and secure multiplug to FIP bracket.
47. Connect feed lead to No.2 glowplug and tighten nut to2.5 Nm.
48. Secure harness clip to dipstick.