See ’R65’, Repairs.

33. Clean compressor pipe and evaporator pipe unions.
34. Lubricate new ’O’ ring with refrigerant oil and fit to compressor pipe.
35. 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.

36. Align air conditioning pipe to bracket on flywheel housing, fit bolt and tighten to 6 Nm.
37. Remove plugs from power steering pump and hose connections.
38. Lubricate new ’O’ ring with clean power steering fluid and fit to fluid outlet hose.
39. 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.

40. Align fluid outlet hose clamp to bracket and secure with bolt.
41. Connect fluid inlet hose to power steering pump and tighten clip.
42. Connect coolant feed hose to expansion tank and tighten clip.
43. Connect 4 engine harness multiplugs to main harness and secure to mounting bracket on bulkhead.
44. Connect multiplug to inertia switch and secure harness clip to mounting bracket.
45. Connect coolant hose to thermostat housing and tighten clip.
46. Connect expansion tank hose to inlet manifold and tighten clip.
47. Connect ECM vacuum pipe to inlet manifold.
48. Connect throttle cable to throttle cam.
49. Locate throttle cable adjusting nut in abutment bracket.
50. Ensure throttle cable is correctly routed and secure to clip on inlet manifold.
51. Connect brake servo vacuum pipe to inlet manifold.
52. Connect hose to fuel return pipe and secure with clip.
53. Clean union of fuel outlet pipe and fuel filter.
54. 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.

55. Fit exhaust front pipe. See MANIFOLD & EXHAUST SYSTEMS, Repairs.
56. Fit evaporative emission canister. See EMISSION CONTROL, Repairs.
57. Connect the engine harness to main harness connector.
58. Connect multiplug to fuse box.
59. Fit positive leads to fuse box and secure with screws.
60. Fit fuse box inner cover.
61. Fit fuse box cover.
62. Connect multiplug to radiator cooling fan.
63. Position earth lead to bonnet locking platform, fit bolt and tighten to 9 Nm.
64. Connect heater hose to coolant outlet elbow and tighten clip.
65. Secure heater hose to clip on coolant rail.
66. Connect radiator bottom hose to coolant rail and tighten clip.
67. Connect radiator top hose to coolant outlet elbow and tighten clip.
68. Connect drive shafts to gearbox as detailed in Differential oil seal. 1.4 & 1.6 models: MANUAL GEARBOX -

See ’R65’, Repairs.

1.8 models: MANUAL GEARBOX -

See ’PG1’, Repairs.

69. Feed clutch cable through abutment bracket and connect to clutch release lever.
70. Position battery tray in vehicle.
71. Tighten 3 bolts securing battery tray to body, to 10 Nm.
72. Position engine compartment fuse box to body, fit bolt and tighten to 10 Nm.