Engine - refitting (manual gearbox in vehicle)

1 Reverse the procedure described in paragraphs 1 to 40, Section 5, noting the following points.

2 Before attempting to refit the engine, 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 Reconnect the clutch cable to the release arm, ensuring that it is routed as noted during removal.

7 Ensure that the roadwheels and the steering wheel are in the straight-ahead position before reconnecting the lower steering column to the intermediate shaft, and tighten the clamp bolt to the specified torque.

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

9 Check the throttle cable adjustment.

10 Fill the cooling system.

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

    See also:

    Instrument panel components - removal and refitting
    Panel illumination and warning lamp bulbs Removal 1 Remove the instrument panel as described in Section 9. 2 Turn the bulbholders anti-clockwise and remove them from the rear of the instrument ...

    Hydraulic pipes and hoses - renewal
    Note: Before starting work, refer to the warning at the beginning of Section 3 concerning the dangers of hydraulic fluid. 1 Always disconnect a flexible hose by prising out the spring anchor clip ...

    Seating
    Notes: Reclining the seatback can cause an occupant to slide under the seat's safety belt, resulting in severe personal injuries in the event of a collision. Do not pile cargo higher than the seat ...