Engine and gearbox (page 8 of 8)

Refit

1. Connect hoist to tool 18G 1598.
2. Using assistance, raise engine and manoeuvre into position in vehicle.
3. Adjust tool 18G 1598 so engine is horizontal in engine compartment.
4. Fit engine RH mounting through bolt but do not tighten.
5. Fit engine LH mounting. See this section.
6. Connect steady bar to engine, fit through bolt and tighten bolt to 45 Nm.
7. Tighten through bolt securing engine steady bar to subframe to 80 Nm.
8. Tighten engine RH mounting through bolt to 80 Nm.
9. Lower hoist and disconnect tool 18G 1598 from engine lifting brackets.
10. Remove lifting brackets 18G 1592 from engine.
11. Clean gear selector linkage and gear selector linkage ball joints.

12. Using tool 18G 1594 connect gear selector linkage ball joint to gear selector lever.
13. Using tool 18G 1594 connect gear change linkage ball joint to gear change lever.
14. Connect drive shafts to gearbox, as detailed in Differential oil seal. See MANUAL GEARBOX - ’R65’, Repairs.
15. Position fuel return hose through clips under inlet manifold and connect to fuel rail, secure with clip.
16. Lubricate new ’O’ ring with silicone grease and fit to fuel feed pipe.
17. Connect feed pipe to fuel rail and tighten bolts to 5 Nm.
18. Connect hose to coolant rail and tighten clip.
19. Connect hose to thermostat housing and tighten clip.
20. Connect coolant hose to inlet manifold and tighten clip.
21. Connect multiplug to inertia switch and secure clip on harness to bracket.
22. Connect engine harness multiplugs to main harness.
23. Connect ECM vacuum pipe to inlet manifold.
24. Connect brake servo vacuum pipe to inlet manifold.
25. Fit evaporative emission canister. See EMISSION CONTROL, Repairs.
26. Connect throttle cable to throttle cam.
27. Secure throttle cable adjusting nut to abutment bracket.
28. Connect front pipe to manifold. See MANIFOLD & EXHAUST SYSTEMS, Repairs.
29. Connect multiplug to HO2S.
30. Connect multiplug to radiator cooling fan.
31. Connect engine harness multiplug to main harness.
32. Position engine harness earth lead to bonnet platform and tighten bolt to 9 Nm.
33. Feed clutch cable through abutment bracket and connect to clutch release lever.
34. Connect heater hose to coolant outlet elbow and tighten clip.
35. Connect radiator bottom hose to coolant rail and tighten clip.
36. Connect radiator top hose to coolant outlet elbow and tighten clip.
37. Position battery tray in vehicle.
38. Tighten 3 bolts securing battery tray to body, to 10 Nm.
39. Fit engine compartment fuse box. See ELECTRICAL, Repairs.
40. Fit 4 bolts securing battery tray to body and tighten to 10 Nm.