Engines fitted with manual timing belt tensioner

10. Fit camshaft cover. See this section.
11. Connect h.t. leads to distributor cap.
12. Connect expansion tank hose to inlet manifold and tighten clip.
13. Connect vacuum hose to inlet manifold.
14. Secure throttle cable to 2 clips on inlet manifold, ensure throttle cable is correctly routed.
15. Connect brake servo vacuum hose to inlet manifold.
16. Connect throttle cable to throttle cam.
17. Locate throttle cable adjusting nut in abutment bracket.
18. Connect purge hose to throttle housing and secure with clip.
19. Remove plugs from fuel system hoses and components.
20. Connect hose to fuel return pipe and secure with clip.
21. Clean union of fuel filter and fuel outlet pipe.
22. Connect fuel outlet pipe to fuel filter and tighten union to 30 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. Secure coolant hose to clip on camshaft rear cover plate.
32. Connect radiator top hose to coolant outlet elbow and tighten clip.
33. Fit new gasket to exhaust manifold flange and connect exhaust front pipe.
34. Fit 4 nuts securing exhaust front pipe to exhaust manifold and tighten to 45 Nm.
35. Fit 2 nuts securing exhaust front pipe to mounting bracket on differential housing and tighten to 25 Nm.
36. Fit alternator top mounting bracket to stud on cylinder head.
37. Connect alternator heatshield to stud on cylinder head.
38. Fit and tighten bolt securing alternator heatshield to mounting bracket.
39. Position alternator in vehicle.
40. Connect 2 cables to alternator and secure with nuts.
41. Fit bolt securing alternator top mounting bracket to cylinder head and tighten to 25 Nm.
42. Fit nut securing alternator top mounting bracket to cylinder head and tighten to 25 Nm.
43. Manoeuvre alternator onto mounting brackets.
44. Fit 2 through bolts securing alternator to mounting brackets, fit 2 nuts and tighten to 45 Nm.
45. Fit camshaft timing belt rear cover to cylinder head and cylinder block.
46. Fit 4 bolts securing camshaft timing belt rear cover to cylinder head and cylinder block and tighten bolts to 9 Nm.
47. Fit 2 camshaft gears to their respective camshafts.

48. Fit bolts and washers securing camshaft gears to camshafts. Using tool 12-182 restrain camshaft gears and tighten bolts to: M8 bolt 35 Nm M10 bolt 65 Nm.
49. Using tool 12-182, align camshaft gear timing marks and fit camshaft gear locking tool 18G 1570 .

Engines fitted with manual timing belt tensioner

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