Engine and gearbox assembly (page 9 of 9)

Refit

1. Lower power unit into vehicle and set horizontal.
2. Position LH support member to sub frame, fit bolts and tighten to 45 Nm.
3. Align mounting bracket to LH mounting, fit bolts and tighten to 45 Nm.
4. Align RH mounting, fit bolt and tighten to 85 Nm.
5. Remove adjustable lifting bracket 18G 1598.
6. Remove lifting brackets tool 18G 1572 from cylinder head.
7. Secure plug leads to clips.
8. Fit both drive shaft and hub assemblies. See REPAIR MANUAL - Manual Gearbox - Differential Oil Seal.

9. Clean gearchange linkage ball joint, and using tool 18G 1594 connect ball joint.
10. Connect steady bar bracket to gearbox, fit bolts and tighten to 85 Nm.
11. Connect oxygen sensor multiplug and secure to bracket.
12. Secure oxygen sensor lead to engine harness with clip.
13. Connect exhaust front pipe to manifold. See MANIFOLD & EXHAUST SYSTEMS, Repairs.
14. Fit starter motor. See REPAIR MANUAL - Electrical.
15. Remove stand(s) and lower vehicle.
16. Position washer reservoir and tighten screws.
17. Connect washer pump multiplugs.
18. Connect servo pipe to manifold.
19. Connect throttle cable to throttle cam and adjust cable. See ENGINE MANAGEMENT SYSTEM - MEMS, Adjustments.
20. Connect fuel return hose and secure clip.
21. Connect fuel feed hose union to filter and using backing spanner, tighten union to 28 Nm.
22. Connect heater hoses and tighten clips.
23. Connect expansion tank hose to inlet manifold and secure clip.
24. Connect expansion tank hose and tighten hose clip.
25. Connect top hose and tighten clip.
26. Clean gearchange upper ball joint, and using tool 18G 1584 connect ball joint.
27. Connect speedo cable.
28. Connect clutch cable to release lever and secure in clip.
29. Fit battery feed cable connector to fuse box and fit 30A fuse and fuse box lid.
30. Secure earth leads to body.
31. Secure oxygen sensor relay to bracket. connect multiplugs to inertia switch, relay module, ECM and harness.
32. Secure harness multiplug to bracket.
33. Position air cleaner support bracket and tighten nuts.
34. Position battery tray and charcoal canister assembly.
35. Position fuse box bracket, fit bolts securing battery tray and tighten to 9 Nm.
36. Connect charcoal canister hose and secure with clip.
37. Connect ECM vacuum hose to inlet manifold.
38. Secure fuse box to bracket.
39. Fit air cleaner. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs.
40. Refill gearbox oil. See REPAIR MANUAL - Maintenance.
41. Refill engine oil. See REPAIR MANUAL - Maintenance.
42. Refill cooling system. See REPAIR MANUAL - Maintenance.
43. Fit bonnet. See REPAIR MANUAL - Body.