Engine and gearbox - models without air conditioning (page 8 of 8)

24. Connect heater hoses to engine coolant rail and secure with clips
25. Connect engine harness to main harness multiplugs and secure to connector mounting bracket.
26. Connect battery lead to starter motor solenoid, fit terminal nut and tighten.
27. Connect lead to engine compartment fusebox, fit and tighten terminal screw.
28. Fit and secure engine compartment fusebox cover.
29. Fit engine management relay module. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs.
30. Secure evaporative emission canister to mounting bracket.
31. Connect multiplug to evaporative emission canister purge valve.
32. Connect evaporative emission canister purge pipe to inlet manifold and secure clip.
33. Remove plugs from fuel pipe and filter.
34. Connect fuel pipe to filter and tighten union to 30 Nm.

CAUTION: To avoid damage to fuel pipes, use 2 spanners when tightening unions.

35. Connect fuel return hose to return pipe and secure with clip.
36. Connect brake servo vacuum pipe to inlet manifold.
37. Connect throttle cable to throttle cam and secure adjusting nut to abutment bracket.
38. Position earth leads to bolt, fit bolt to gearbox and tighten to 35 Nm.
39. Position battery tray mounting bracket and connect vacuum hose to cruise control vacuum control unit.
40. Connect multiplugs to dim dip resistor and cruise control vacuum control unit.
41. Position battery tray mounting bracket to fixings, do not tighten at this stage.
42. Position air intake hose to battery tray mounting bracket and secure with bolt.
43. Position battery tray to mounting bracket.
44. Fit bolts and nut securing battery tray to mounting bracket and engine LH mounting.
45. Tighten 2 bolts securing battery tray mounting bracket to body to 9 Nm .
46. Fit air cleaner. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs.
47. Connect LH drive shaft to gearbox as detailed in LH Differential oil seal. See MANUAL GEARBOX - ’PG1’, Repairs.
48. Connect RH drive shaft to gearbox as detailed in RH Differential oil seal. See MANUAL GEARBOX - ’PG1’, Repairs.
49. Position engine lower tie bar to sump bracket, fit bolt and tighten to 100 Nm.
50. Tighten engine lower tie bar to rear beam bolt to 100 Nm.
51. Connect selector rod to selector shaft and align holes.
52. Fit new roll pin securing selector rod to shaft and fit roll pin retaining clip.
53. Fit washers to gear change steady bar and connect steady bar to gearbox.
54. Fit bolt securing steady bar to gearbox and tighten to 10 Nm.
55. Fit underbelly panel. See BODY, Exterior fittings.
56. Fit road wheel(s) and tighten nuts to correct torque. See INFORMATION, Torque wrench settings.
57. Remove stand(s) and lower vehicle.
58. Tighten bolts and nuts, suspension forks to lower arms, to 64 Nm.
59. Tighten bolt securing engine RH mounting tie bar to body bracket to 100 Nm.
60. Tighten bolt securing engine RH mounting tie bar to mounting to 100 Nm.
61. Align PAS reservoir to body, fit bolts and tighten to 9 Nm.
62. Fit radiator cooling fan. See COOLING SYSTEM, Repairs.
63. Connect battery earth lead.
64. If required: Refill engine with oil. See MAINTENANCEMaintenance.
65. Fill gearbox with correct grade of oil. See MANUAL GEARBOX - ’PG1’, Adjustments.
66. Refill cooling system. See COOLING SYSTEM, Adjustments.
67. Bleed power steering system. See STEERING, Adjustments.
68. Adjust throttle cable. See ENGINE MANAGEMENT SYSTEM - MEMS, Adjustments.