DISCONNECTING LOOM



1. Disconnect battery removing neg earth first.

2. Remove left hand upper 10mm bolt on battery hold down bar. Only loosen the right hand bolt partially to allow the bar to be swivelled out of the way.

3. Remove battery.

4. Remove the 3 x 13mm bolts at the bottom of the battery tray and lift out noting route of the water drain pipe at the bottom of the tray.

5. Remove 3 x plugs which connect onto the fuel filter (2 x front 1 x left). Then unclip the wiring from the bulkhead.

6. Reach into the scuttle area behind the fuel filter and remove the 2 x 10mm bolts holding the black splash cover over the ECU. The 2 x ECU plugs can now be taken out by, firstly, sliding the locks out each plug (left for left plug and right for right plug). Ensure you take the two plugs straight out as you dont want to bend the small pins on the ECU. Leave the ECU in situ but replace the cover if the car is outside.

7. Pull the cabling from the ECU into the engine bay by removing the 2 x 10mm round topped bolts from where it joins the bulkhead . Note where it routes under the wiper mechanism to prevent the wires fouling on refitting.

8. Look for the black box to the left of the fuel filter and remove the two plugs. One is for the glow plug loom which is a bunch of cable on its own.

9. To the front of the gear box, remove both the reverse switch and engine block earth. Tuck these out the way behind the nearside headlight.

10. Lift the black lid from the engine compartment fuse box then, using a flat blade screwdriver to the tags on the right hand side, lift the fuse box from its base. You will then need to remove whatever cabling exits the top of the fuse box. 1 x large plug and 1 x 50amp fuse. 2 x small plugs to the left hand side.

11. Separate the battery terminal wires so that what can stay with the car body does so and what can be kept with the engine does likewise. Dont worry, on reconnection these wires are all coloured red and black respectively so there is no doubt as to where they go.

12. Pull the plug(s) for the radiator fan(s) and unclip the cabling from the radiator. The cable can now be freed from the clip near the turbo and tucked behind the nearside headlight.

13. Pull the plug from the MAF sensor located mid way down the hose which leads from the top of the air filter housing.

14. If you have air con, remove the plug from the pump at the front left of the engine. This is due to the air con components having to stay with the car to prevent breaking the air con piping and losing your fluid etc.



ALL WIRING SHOULD NOW BE FREE. THE WIRING SHOULD NOW BE PLACED ON TOP OF THE ENGING AND HELD DOWN TO THE INTAKE MANIFOLD WITH CABLE TIES TO KEEP IT SAFE DURING REMOVAL. ALL OTHER PLUGS AND “ON ENGINE” CABLING CAN BE REMOVED ON THE GROUND WHERE ACCESS IS BETTER AS THE LOOM WILL COME OUT WITH THE ENGINE.