Air conditioning

4. Fit R.H. mounting plate, tighten bolts 55 Nm. Fit through bolt and washer, do not tighten.
5. Align rear mounting bracket to gearbox; tighten bolts to 55 Nm. Fit NEW though bolt, do not tighten.
6. Finally tighten mounting through bolts in sequence as follows:
   • Rear mounting through bolt 60 Nm.
   • Front mounting through bolt 60 Nm.
   • R.H. mounting through bolt 60 Nm.
   • L.H. mounting through bolt 55 Nm.
7. Disconnect lifting chains from bracket.
8. Remove engine lifting bracket and spacer.
9. Connect R.H. drive shaft to differential, see MANUAL GEARBOX 1.6 – Repairs – Differential oil seal – R.H.
10. Connect L.H. drive shaft to intermediate shaft, see MANUAL GEARBOX 1.6 – Repairs – Differential oil seal – L.H.
11. Fit starter motor, see ELECTRICAL – Repairs.
12. Connect L.H. engine harness at multiplugs.
13. Secure engine harness multiplugs to brackets.
14. Connect vacuum pipes to inlet manifold.
15. Connect brake servo vacuum hose to pipe.
16. Air conditioning: Secure pipe to clip.
17. Connect gear change steady bar and selector rod; tighten bolt to 35 Nm.
18. Align pin holes and fit roll pin to retain selector rod.
19. Secure roll pin with spring clip and fit gaiter.
20. Fit front exhaust pipe, see MANIFOLD & EXHAUST – Repairs.
21. Connect clutch cable to release lever, see CLUTCH – Repairs – Clutch Cable – 1.6.
22. Connect reverse lamp leads at snap connectors.
23. Connect speedometer cable to gearbox, secure retaining clip by rotating gaiter.
24. Connect heater hoses to engine, tighten clips.
25. Connect coolant hoses to engine, tighten clips.

Air conditioning

26. Locate compressor and fit securing bolts, tighten to 25 Nm.
27. Fit and tension compressor drive belt, see MAINTENANCE

Power steering

28. Locate power steering pump and fit securing bolts, tighten to 35 Nm.
29. Locate power steering hose in clip.
30. Position power steering pipe clamp; tighten bolt to 15 Nm.
31. Fit and tension power steering pump drive belt, see MAINTENANCE

All models

32. Connect throttle cable to linkage and locate abutment bracket.
33. Secure throttle cable with retaining clips.
34. Adjust throttle cable, see ENGINE MANAGEMENT SYSTEM PGM – Fi – Adjustments.
35. Fit distributor, see ENGINE MANAGEMENT SYSTEM PGM – Fi – Repairs.
36. Connect fuel outlet pipe to filter, tighten banjo bolt to 32 Nm.
37. Connect earth lead to gearbox, tighten bolt to 35 Nm.
38. Fit battery lead to fusebox and tighten screw, fit fuse cover plate and fusebox cover.
39. Connect R.H. engine harness at multiplugs and secure harness with strap.
40. Fit battery tray, tighten bolts to 9 Nm.
41. ABS 6: Attach ABS pipe clip to battery tray, tighten bolt to 9 Nm.
42. Connect trunking to throttle housing and breather pipe and connect to air cleaner, tighten clip.
43. Connect vacuum pipe to air cleaner and secure in clips.
44. Fit air duct and clip expansion tank hose on top.
45. Fit side branch to air duct and engage clip.
46. Connect PCV pipe to trunking and camshaft cover and tighten clips.
47. Connect engine earth cable to bonnet lock platform.
48. Fit battery into tray, fit clamp and tighten bolt; connect both battery leads.
49. Fit underbelly panel, see BODY – Repairs.
50. Remove stand(s) and lower vehicle.
51. Fill gearbox with correct quantity and grade of oil, see INFORMATION – CAPACITIES, FLUIDS AND LUBRICANTS
52. Fill engine with correct quantity and grade of oil, see INFORMATION – CAPACITIES, FLUIDS AND LUBRICANTS
53. Refill cooling system, see MAINTENANCE
54. Fit bonnet, see BODY – Repairs.
55. Check ignition timing, see MAINTENANCE