Engine and automatic gearbox - models without air conditioning (page 9 of 9)

11. Lower hoist and disconnect lifting bracket tool 18G 1598 from lifting brackets.
12. Remove bolt securing lifting bracket tool 18G 1572/2 to cylinder head and remove lifting bracket.
13. Remove 2 bolts securing lifting bracket tool 18G 1572/1 to cylinder head and remove lifting bracket.
14. Clean camshaft rear cover plate.
15. Position camshaft rear cover plate to cylinder head, fit bolts and tighten to 25 Nm.
16. Connect engine steady bar to bracket on sump, fit through bolt and tighten to 80 Nm.
17. Tighten through bolt, engine steady bar to subframe, to 80 Nm.
18. Remove plugs from fluid cooler hose unions, lubricate new ’O’ rings with gearbox and fit to unions.
19. Connect fluid cooler hoses to gearbox and tighten unions to 37 Nm.
20. Fit selector cable to abutment bracket and push anti-vibration rubbers into position.
21. Tighten selector cable lock nut to abutment bracket.
22. Slide selector cable rod sleeving into position.
23. Connect selector cable rod to selector rod, DO NOT tighten nut.
24. Remove plugs from power steering pump and hose connections.
25. Lubricate new ’O’ ring with clean power steering fluid and fit to fluid outlet hose.
26. 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.

27. Align fluid outlet hose clamp to bracket and secure with bolt.
28. Connect fluid inlet hose to power steering pump and tighten clip.
29. Connect coolant feed hose to expansion tank and tighten clip.
30. Connect 4 engine harness multiplugs to main harness and secure to mounting bracket on bulkhead.
31. Connect multiplug to inertia switch and secure harness clip to mounting bracket.
32. Connect coolant hose to thermostat housing and tighten clip.
33. Connect expansion tank hose to inlet manifold and tighten clip.
34. Connect ECM vacuum pipe to inlet manifold.
35. Connect throttle cable to throttle cam.
36. Locate throttle cable adjusting nut in abutment bracket.
37. Ensure throttle cable is correctly routed and secure to clip on inlet manifold.
38. Connect brake servo vacuum pipe to inlet manifold.
39. Connect hose to fuel return pipe and secure with clip.
40. Clean union of fuel outlet pipe and fuel filter.
41. 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.

42. Fit exhaust front pipe. See MANIFOLD & EXHAUST SYSTEMS, Repairs.
43. Fit evaporative emission cansiter. See EMISSION CONTROL, Repairs.
44. Connect the engine harness to main harness connector.
45. Connect multiplug to fuse box.
46. Fit positive leads to fuse box and secure with screws.
47. Fit fuse box inner cover.
48. Fit fuse box cover.
49. Connect multiplug to radiator cooling fan.
50. Position earth lead to bonnet locking platform, fit bolt and tighten to 9 Nm.
51. Connect heater hose to coolant outlet elbow and tighten clip.
52. Secure heater hose to clip on coolant rail.
53. Connect radiator bottom hose to coolant rail and tighten clip.