That's the engine basically built up now, alternator, EGR, water pump, tensioner, cam cover, vacuum pump, wiring loom, air inlet valve assembly, heat shields are all back in place. This stage of the job was the most enjoyable/ easy.
At this point, I plugged the air mass meter back in, fitted a new oil filter and fresh oil and attempted to start the engine.
Battery reconnected, I turned the key and waited for the fuel pump to prime. Took a brave pill and turned the engine over. It turned over and over with no sign of life. This was because there was no fuel in the entire system. The injectors won't even fire until the ECU sees sufficient fuel pressure. After a few goes, and more cranking, the engine fired into life, seemingly like nothing had happened. No smoke, no rattles, no miss firing. The advantage of common-rail systems I suppose.
Anyway, I only ran it for a few seconds as there was no coolant in the engine, but all lights went out, it sounded fine. Result.
Now it was time to put the radiators/ front clip back on. I hate doing this. The water radiator, electric fan assembly, intercooler, air con condenser and oil cooler pipes are like a puzzle. They all go together in one way, and you have to build them into the front panel in a certain way- no short cuts!
First, the rad attaches to the intercooler. Then the fan unit attaches to them both. Then you squeeze that lot into the front clip. 20190429_115936
by David James
, on Flickr