Engine/manual gearbox assembly - reconnection and refitting

1 Reverse the procedure described in paragraphs 1 to 33 of Section 7, noting the following points.

2 Before attempting to reconnect the engine to the gearbox, check that the clutch friction disc is centralised.

3 Check that the clutch release arm and bearing are correctly fitted, and lightly grease the input shaft splines.

4 Check that the engine adapter plate is correctly positioned on its locating dowels. If necessary, a cable-tie can be used to temporarily secure the adapter plate in position on the cylinder block, using one of the engine-to-gearbox bolt holes.

5 If shims were fitted between the sump and the gearbox, refit them in their original locations when mating the engine to the gearbox. If the engine has been overhauled, where applicable fit the relevant shims as calculated during engine reassembly.

6 Ensure that the roadwheels and the steering wheel are in the straight-ahead position before reconnecting the lower steering column to the intermediate shaft.

7 Reconnect the clutch cable to the release arm, ensuring that it is routed as noted during removal.

8 Fill the engine with the correct grade and quantity of oil.

9 Check the throttle cable adjustment.

10 Fill the cooling system.

11 Check and if necessary top-up the gearbox oil level.

12 Tighten all fixings to the specified torque, where applicable.

    See also:

    Alternator brushes and regulator - renewal
    Bosch alternator 1 With the alternator removed from the engine, clean the external surfaces free from dirt. 2 Extract the brush box/regulator screws from the rear cover and withdraw the brush bo ...

    Crankshaft front oil seal - renewal
    1 Disconnect the battery negative lead. 2 Slacken the alternator mounting and adjuster bolts and after pushing the alternator in towards the engine, slip off the drivebelt. 3 Unscrew and remove th ...

    Multi-function lever
    Windshield wiper: For intermittent wiping, move the control down one position and rotate the wiper switch to the desired position. For low speed wiping, move the control down two positio ...