All Models

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. Clean air conditioning pipe connections.
29. Lubricate new ’O’ rings with refrigerant oil and fit to air conditioning pipes.
30. Connect unions and tighten to 25 Nm

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

31. Connect vacuum pipe to EGR valve.
32. Connect brake servo vacuum hose to pipe at camshaft cover and secure with clip.
33. Connect coolant hose to heater valve and secure hose with clip.
34. Connect top hose to radiator and tighten hose clip.
35. Connect heater hose to coolant rail and tighten hose clip.
36. Connect fuel feed and return hoses to pipes and secure hoses with clips.
37. Connect battery negative lead to starter solenoid and secure with nut.
38. Position harness to engine and secure clips at coolant rail.
39. Connect multiplug to vehicle speed sensor.
40. Connect multiplug to CKP sensor.
41. Position earth leads to gearbox, fit bolt and tighten to 35 Nm.
42. Connect Lucar to starter solenoid.
43. Connect reverse lamp switch leads to harness.
44. Connect multiplug(s) to FIP.
45. Secure harness clip to bracket on FIP.
46. Connect multiplug to alternator.
47. Connect lead to alternator terminal, fit and tighten nut and reposition terminal cover.
48. Connect multiplugs to cooling fan and and air conditioning compressor.
49. Connect injector lift sensor multiplug and secure multiplug to FIP bracket.
50. Connect feed lead to No.2 glowplug and tighten nut to2.5 Nm.
51. Secure harness clip to dipstick.
52. Connect multiplug to ECT sensor.
53. Connect coolant temperature gauge sensor Lucar to harness.
54. Secure harness clips to camshaft drive belt cover.
55. Connect multiplug to EGR solenoid.
56. Connect multiplug to engine oil temperature switch.
57. Connect multiplug to oil pressure switch.
58. Align and harness to oil pump and secure with cable tie.

All Models

59. Clean 2 ends of clutch hydraulic pipe.
60. Connect 2 halves of clutch hydraulic pipe, ensure 2 halves are correctly engaged by trying to pull hydraulic pipes away from connectors.
61. Fit battery tray and secure with 4 bolts and a nut.
62. Connect multiplug to dim dip resistor.
63. Fit air hose to turbocharger and tighten hose clip.
64. Connect multiplug to MAF sensor.
65. Replace receiver/drier. See AIR CONDITIONING, Repairs.
66. Recharge air conditioning system. See AIR CONDITIONING, Adjustments.

Models with intercooler

67. Fit bottom hose to intercooler and tighten clip.
68. Connect intercooler bottom hose to plenum chamber and tighten clip.
69. Fit top hose to intercooler and tighten clip.
70. Connect intercooler top hose to turbocharger pipe and tighten clip.