Models with air conditioning only

Refit

1. Fit engine assembly into position using assistance.
2. Fit engine RH mounting assembly.
3. Align engine mounting assembly.
4. Fit 3 bolts securing engine mounting to engine and tighten to 105 Nm.
5. Fit mounting restraint bar to mounting, fit and tighten 2 nuts to 45 Nm.
6. Align mounting tie bar to body bracket, fit and tighten bolt to 80 Nm.
7. Tighten bolt securing mounting tie bar to mounting to 80 Nm.
8. Align engine LH mounting to bracket.
9. Fit engine LH mounting, tighten M10 nuts to 45 Nm and M12 nut to 70 Nm.
10. Release lifting tool chains from engine.
11. Remove lifting tool 18G 1598.
12. Using assistance, fit front beam to vehicle. Fit bolts and tighten to 69 Nm.
13. Fit engine lower steady bar. See this section.
14. Fit LH and RH radius arms to lower arms and tighten bolts to 105 Nm.
15. Clean splines of both drive shafts and fit new circlip.
16. Smear both differential oil seals with clean engine oil.
17. Insert drive shafts into differential and push fully home until circlip locks into differential. Pull on inner joint housing to ensure circlip is fully engaged.

CAUTION: Keep drive shaft horizontal to avoid damaging differential oil seal.

18. Engage swivel pins in lower arms and tighten castellated nuts to 50 Nm. Align nuts to allow fitment of split pins.
19. Fit NEW split pins to castellated nuts.
20. Engage damper forks on dampers, ensuring tabs are aligned with slots in forks.
21. Fit but do not tighten pinch bolts and lower arm bolts.

NOTE: Pinch bolts and lower arm bolts should be tightened with the vehicles weight acting on the suspension.

22. Position steady bar and gear selector rod.
23. Align holes in selector shaft and selector rod.
24. Fit selector rod roll pin and secure with retaining clip.
25. Fit bolt and washers securing steady bar and tighten to 60 Nm.
26. Fit exhaust front pipe. See REPAIR MANUAL - Manifold & Exhaust Systems, Repairs.
27. Fit centre beam and tighten bolts to 55 Nm.
28. Connect PAS pump feed hose to fluid reservoir and tighten clip.

Models with air conditioning only

29. Lubricate new ’O’ rings with refrigerant oil and fit to air conditioning pipes.
30. Fit air conditioning pipes to compressor and tighten bolt to 17 Nm.
31. Fit and tighten bolt securing air conditioning pipe to bonnet locking platform.

All models

32. Connect coolant heater hose to engine and tighten clip.
33. Connect boost pressure sensing pipe to turbocharger.
34. Connect vacuum pipe to vacuum pump and secure with clip.
35. Fit and tighten bolt securing vacuum pipe to camshaft cover.
36. Connect vacuum hose to EGR valve.
37. Secure fuel filter to mounting bracket.
38. Connect fuel hose to fuel filter and secure with clip.
39. Connect fuel return hose to pipe and secure with clip.
40. Connect expansion tank and heater hoses to coolant rail and secure with clips.
41. Fit bolt and two washers to power steering pipe banjo. Fit banjo to pump and tighten bolt to 55 Nm.
42. Fit coolant hose to engine oil cooler inlet pipe and tighten clip.
43. Connect coolant hose to radiator outlet pipe and secure with clip.
44. Fit hose to coolant rail and secure with clip.
45. Connect coolant hose to engine oil cooler inlet pipe and secure with clip.
46. Fit hose to coolant pump and secure with clip.
47. Connect coolant hose to radiator inlet pipe and secure with clip.
48. Connect hose to coolant outlet elbow and secure with clip.