Engines fitted with manual timing belt tensioner

22. Connect fuel outlet pipe to fuel filter and tighten union to 28 Nm.
23. Connect multiplug to IACV.
24. Connect HO2S multiplug to engine harness and secure to clip on bracket.
25. Secure coil h.t. lead to clip on bracket and connect to distributor cap.
26. Connect multiplug to IAT sensor.
27. Connect multiplug to injector harness.
28. Connect multiplug to TP sensor.
29. Connect multiplugs to ECT sensors.
30. Connect coolant hose to coolant outlet elbow and tighten clip.
31. Connect radiator top hose to coolant outlet elbow and tighten clip.
32. Fit new gasket to exhaust manifold flange and connect exhaust front pipe.
33. Fit 4 nuts securing exhaust front pipe to exhaust manifold and tighten to 45 Nm.
34. Fit alternator top mounting bracket to stud on cylinder head.
35. Connect alternator heatshield to stud on cylinder head.
36. Fit and tighten bolt securing alternator heatshield to mounting bracket.
37. Position alternator in vehicle.
38. Connect 2 cables to alternator and secure with nuts.
39. Fit bolt securing alternator top mounting bracket to cylinder head and tighten to 25 Nm.
40. Fit nut securing alternator top mounting bracket to cylinder head and tighten to 25 Nm.
41. Manoeuvre alternator onto mounting brackets.
42. Fit 2 through bolts securing alternator to mounting brackets, fit 2 nuts and tighten to 45 Nm.
43. Fit camshaft timing belt rear cover to cylinder head and cylinder block.
44. Fit 4 bolts securing camshaft timing belt rear cover to cylinder head and cylinder block and tighten bolts to 10 Nm.
45. Fit 2 camshaft gears to their respective camshafts.

46. Fit bolts and washers securing camshaft gears to camshafts. Using tool 12-182 restrain camshaft gears and tighten bolts to: M8 Bolts - 35 Nm M10 Bolts - 65 Nm
47. Using tool 12-182 align camshaft gear timing marks and fit tool 18G 1570 to camshaft gears.

Engines fitted with manual timing belt tensioner

48. Fit camshaft timing belt tensioner to cylinder head.
49. Fit tensioner pulley Allen bolt.
50. Connect tensioner spring to tensioner and to stud on cylinder head.
51. Push tensioner pulley down to fully OFF position, fit and tighten backplate bolt to 10 Nm.

All engines

52. Fit new camshaft timing belt. See this section.
53. Remove stand(s) and lower vehicle.
54. Refill cooling system. See COOLING SYSTEM - ’K’ SERIES, Adjustments.
55. Connect battery earth lead.
56. Adjust throttle cable. See ENGINE MANAGEMENT SYSTEM - MEMS, Adjustments.