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:

    Engine Coolant Temperature (ECT) sensor - removal and refitting
    Removal 1 The ECT sensor is screwed into the inlet manifold. 2 Disconnect the battery negative lead. 3 Partially drain the cooling system as described in Chapter 1. 4 Disconnect the sensor wirin ...

    Idle speed compensator - removal and refitting
    Removal 1 The idle speed compensator is only fitted to K-Jetronic systems from 1986 onwards and is located in the centre of the engine compartment bulkhead (see illustration). 19.1 K-Jetronic s ...

    Speedometer cable - removal and refitting
    Removal 1 On models fitted with a trip computer, remove the speed sender unit. 2 Remove the instrument panel. 3 Pull the cable through the bulkhead into the engine compartment, and where applicab ...