Flywheel housing cover (page 5 of 5)

Refit

1. Clean flywheel housing cover and mating face of flywheel housing.
2. Manoeuvre cover through gap between brake master cylinder and engine.
3. Position cover to flywheel housing.
4. Raise engine on jack.
5. Fit and tighten bolts securing cover to flywheel housing.
6. Lower engine on jack and align engine RH mounting to subframe.
7. Fit bolts, washers and nuts securing engine mounting to subframe.
8. Remove jack supporting engine.
9. Align engine lower steady bar to bracket on flywheel housing and position washers.
10. Fit bolt and nut securing engine lower steady bar to flywheel housing bracket and tighten to 40 Nm.
11. Fit brake master cylinder to studs on servo, fit nuts and tighten to 25 Nm.
12. Position clutch slave cylinder mounting bracket and spacer to flywheel housing.
13. Fit 3 bolts securing mounting bracket to flywheel housing, tighten bolts: M8 bolts to 37 Nm. M5 bolt to 7 Nm.
14. Fit clutch slave cylinder onto push rod.
15. Align slave cylinder to mounting bracket, fit bolts and tighten to 37 Nm.
16. Depress clutch pedal to load clutch lever and remove any free play.

17. Measure clearance between throw out stop lock nut and flywheel housing cover.
18. The correct clearance is 6.5 mm. If the clearance is incorrect, loosen lock nut and adjust throw out stop to obtain correct clearance.
19. Tighten lock nut and recheck clearance.
20. Secure battery feed cable grommet to bracket on flywheel housing.
21. Position engine harness retaining bracket to flywheel housing, fit bolt and tighten to 25 Nm.
22. Connect Lucar to bonnet switch.
23. Position earth leads to body, fit bolt and tighten to 9 Nm.
24. Fit fresh air intake duct to inner wing.
25. Connect fresh air intake hose to duct beneath wing.
26. Locate ECM mounting bracket on body, fit bolt and tighten to 10 Nm.
27. Secure clip on main harness to ECM mounting bracket.
28. Secure engine compartment fuse box to ECM mounting bracket.
29. Connect engine harness lead to engine compartment fuse box.
30. Fit fusible link.
31. Fit cover to engine compartment fuse box.
32. Fit engine breather/oil separator. See EMISSION CONTROL, Repairs.
33. Fit ECM. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs.
34. Fit bonnet. See BODY, Exterior fittings.
35. Fit starter motor. See ELECTRICAL, Repairs.