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:

    Coil - testing, removal and refitting
    Testing All models except 1.6 and 1.8 litre CVH (R6A type) 1 The coil is located on the left-hand side of the engine compartment and is retained by a metal strap (see illustration). It is of high ...

    General description
    The braking system is of the dual circuit hydraulic type with disc brakes at the front and drum brakes at the rear. A diagonally split dual circuit hydraulic system is employed in which each circu ...

    Inner gutter weatherstrip (Saloon, Hatchback and Estate models) - removal and refitting
    Removal 1 Open both the front and rear doors to expose the relevant weatherstrip. 2 Carefully pull the weatherstrip from the base of the front pillar, taking care to release the flap which is stu ...