Power steering

16. Fit camshaft alignment tools 18G 1580.
17. Position camshaft upper rear cover, tighten bolt to 10 Nm.
18. Fit camshaft front oil seals and pulleys.
19. Fit camshaft timing belt.
20. Fit starter motor, see ELECTRICAL – Repairs
21. Tension camshaft timing belt, see ENGINE – 1.6 – Adjustments.
22. Check and adjust valve clearances, see MAINTENANCE.
23. Connect exhaust front pipe, see MANIFOLD & EXHAUST – Front pipe and flange gasket.
24. Position wiring harness to fuel rail and inlet manifold.
25. Connect 4 multiplugs to injectors.
26. Fit 2 nuts and bolt to secure cover and harness; tighten nuts and bolt to 22 Nm.
27. Fit 2 bolts securing inlet manifold to support bracket; tighten bolts to 22 Nm.
28. Secure multiplug to bracket on inlet manifold.
29. Fit distributor, see ENGINE MANAGEMENT SYSTEM – PGM – Fi – Repairs.
30. Fit new 'O' ring to T.D.C sensor, fit sensor and tighten bolts to 12 Nm.
31. Connect multiplug to throttle angle sensor.
32. Connect T.A. sensor multiplug to inlet manifold.
33. Connect 2 coolant sensor multiplugs at cylinder head.
34. Connect air cleaner and MAP sensor hoses to inlet manifold.
35. Connect T.D.C. sensor multiplug.
36. Connect heater hoses and tighten clip.
37. Connect top hose and tighten clip.
38. Automatic gearbox: Connect throttle control cable to lever.
39. Connect throttle cable and tighten locknut.
40. Connect fuel return hose to fuel rail and tighten clip.
41. Connect fuel output pipe to fuel filter; use new sealing washers.
42. Connect brake servo hose to inlet manifold and tighten clip.

Power steering

43. Locate power steering pump on mounting bracket, fit bolts and tighten to 35 Nm.
44. Locate power steering hose in clip.
45. Position power steering pipe clamp, tighten bolt to 15 Nm.
46. Fit and tension power steering pump drive belt, see MAINTENANCE.

All models

47. Connect trunking to air cleaner and throttle housing, tighten clips.
48. Connect P.C.V. hose to air intake trunking and camshaft cover, tighten clips.
49. Locate vacuum hose in clips, connect vacuum hose to air cleaner.
50. Refill cooling system, see MAINTENANCE.
51. Connect battery earth lead.
52. Remove stand(s) and lower vehicle.
53. Automatic gearbox: Adjust throttle control cable, see AUTOMATIC GEARBOX – 1.6 – Adjustments.
54. Set ignition timing, see MAINTENANCE.

OIL COOLER

Service Repair No. 12.06.68

Remove

1. Remove oil filter see MAINTENANCE.

2. Release 2 clips and disconnect inlet and outlet hoses from oil cooler.
3. Remove oil filter adaptor and collect oil cooler and discard O – ring seal.

Refit

1. Clean oil cooler and engine block oil cooler mounting faces.
2. Lubricate new O – ring with clean engine oil.
3. Position oil cooler and O – ring on engine block.
4. Secure coupler with oil filter adaptor and tighten to 10 Nm
5. Fit inlet and outlet hoses to oil cooler and secure with clips.
6. Fit oil filter.