Engine and manual gearbox assembly (page 10 of 10)

Refit

1. Position engine table under body, and carefully lower body onto engine and gearbox assembly.
2. Align subframe to body and loosely fit subframe bolts.

NOTE: Fit rear anti-roll bar mounting brackets to subframe rear mounting bolts.

3. Carefully lower body remaining distance onto subframe and tighten bolts to; Subframe front bolts = 30 Nm. Subframe rear bolts = 45 Nm.
4. Raise vehicle and remove engine table.
5. Fit nuts securing anti-roll bar to mounting brackets and tighten to 13 Nm.
6. Fit rear RH brake caliper to hub, fit bolts and tighten to 85 Nm.
7. Fit rear LH brake caliper to hub, fit bolts and tighten to 85 Nm.
8. Position RH handbrake cable to caliper and secure with clevis pin and NEW ’R’ clip.
9. Fit NEW spring clip securing RH handbrake cable to caliper abutment bracket.
10. Position LH handbrake cable to caliper and secure with clevis pin and NEW ’R’ clip.
11. Fit NEW spring clip securing LH handbrake cable to caliper abutment bracket.
12. Fit silencer heat shield. See MANIFOLD & EXHAUST SYSTEMS, Repairs.
13. Fit selector cables to gearbox abutment brackets and secure with NEW spring clips.
14. Clean Hydragas pipe unions.
15. Lubricate NEW ’O’ rings and fit to Hydragas pipe unions.
16. Connect Hydragas pipes under floorpan and tighten to 20 Nm.
17. Fit pipes to coolant rail on underside of vehicle and secure with clips.
18. Fit road wheel(s) and tighten nuts to correct torque. See INFORMATION, Torque wrench settings.
19. Lower vehicle.
20. Lubricate NEW ’O’ ring and fit to speedometer cable.
21. Fit speedometer cable to gearbox and tighten bolt to 19 Nm.
22. Connect LH and RH ABS sensor leads.
23. Position engine harness earth leads to body, fit earth bolt and tighten.
24. Connect cannister purge valve multiplug.
25. Connect vacuum pipe to ECM.
26. Connect engine harness and relay unit multiplugs.
27. Fit ECM bracket and tighten bolts to 8 Nm.
28. Connect ECM multiplug.
29. Fit Lucar and starter motor feed lead to solenoid and tighten nut.
30. Secure cables to solenoid body with cable tie.
31. Connect coolant hose to underside of reservoir and secure with clip.
32. Connect coolant hose to inlet manifold and secure with clip.
33. Connect vacuum pipe to inlet manifold.
34. Connect vacuum pipe between inlet manifold and ECM.
35. Connect fuel return hose to fuel pipe.
36. Connect fuel feed hose to fuel filter.
37. Connect throttle cable to throttle cam and abutment.
38. Secure throttle cable to clip on inlet manifold.
39. Connect pipe from cannister purge valve to throttle body and secure with clip.
40. Fit bolts securing clutch slave cylinder to mounting bracket.
41. Fit push rod to clutch slave cylinder.
42. Fit clevis pin and washer between push rod and release lever and secure with ’R’ clip.
43. Fit air intake pipe and secure with clips.
44. Connect hose to coolant rail and secure with clip.
45. Connect hose assembly between coolant outlet elbow, heater coolant rail, and feed hose to coolant reservoir, and secure with clips.
46. Connect hose to coolant outlet elbow and secure with clip.
47. Refill coolant system. See COOLING SYSTEM, Adjustments.
48. Fit engine cover. See this section.
49. Fit engine compartment access panel. See BODY, Exterior fittings.
50. Connect battery earth lead.
51. Pressurise Hydragas system and set correct trim height. See FRONT SUSPENSION, Adjustments.