See ’R65’, Adjustments. (page 11 of 11)

24. Remove caps from air conditioning pipes and compressor.
25. Clean mating faces of air conditioning pipe union and compressor.
26. Lubricate 2 new ’O’ rings with refrigerant oil and fit to compressor.
27. Position air conditioning pipe union to compressor, fit bolt and tighten to 35 Nm.
28. Clean condenser pipe and compressor pipe unions.
29. Lubricate new ’O’ ring with refrigerant oil and fit to condenser pipe.
30. Connect condenser pipe to compressor pipe, fit bolt and tighten to 6 Nm.
31. Clean compressor pipe and evaporator pipe unions.
32. Lubricate new ’O’ ring with refrigerant oil and fit to compressor pipe.
33. Connect evaporator pipe to compressor pipe and tighten union to 45 Nm.

CAUTION: To prevent damage to air conditioning pipes and components use two spanners when loosening or tightening unions.

34. Align air conditioning pipe to bracket on flywheel housing, fit bolt and tighten to 6 Nm.
35. Remove plugs from power steering pump and hose connections.
36. Lubricate new ’O’ ring with clean power steering fluid and fit to fluid outlet hose.
37. Connect fluid outlet hose to power steering pump and tighten union to 55 Nm.

CAUTION: To prevent damage to components, use two spanners when loosening or tightening unions.

38. Align fluid outlet hose clamp to bracket and secure with bolt.
39. Connect fluid inlet hose to power steering pump and tighten clip.
40. Connect coolant feed hose to expansion tank and tighten clip.
41. Connect 4 engine harness multiplugs to main harness and secure to mounting bracket on bulkhead.
42. Connect multiplug to inertia switch and secure harness clip to mounting bracket.
43. Connect coolant hose to thermostat housing and tighten clip.
44. Connect expansion tank hose to inlet manifold and tighten clip.
45. Connect ECM vacuum pipe to inlet manifold.
46. Connect throttle cable to throttle cam.
47. Locate throttle cable adjusting nut in abutment bracket.
48. Ensure throttle cable is correctly routed and secure to clip on inlet manifold.
49. Connect brake servo vacuum pipe to inlet manifold.
50. Connect hose to fuel return pipe and secure with clip.
51. Clean union of fuel outlet pipe and fuel filter.
52. Connect fuel outlet pipe to fuel filter and tighten union to 28 Nm.

CAUTION: To prevent damage to fuel system pipes and components use two spanners when loosening or tightening unions.

53. Fit exhaust front pipe. See MANIFOLD & EXHAUST SYSTEMS, Repairs.
54. Fit evaporative emission cansiter. See EMISSION CONTROL, Repairs.
55. Connect the engine harness to main harness connector.
56. Connect multiplug to fuse box.
57. Fit positive leads to fuse box and secure with screws.
58. Fit fuse box inner cover.
59. Fit fuse box cover.
60. Connect multiplug to radiator cooling fan.
61. Position earth lead to bonnet locking platform, fit bolt and tighten to 9 Nm.