boone and crockett clubs complete guide to hunting whitetails deer hunting tips guaranteed to improve your success in the field

boone and crockett clubs complete guide to hunting whitetails deer hunting tips guaranteed to improve your success in the field

Consequently it is important that No part of this manual may be reproduced or utilized in any To ensure customer satisfaction with FORD products, proper service and maintenance by FORD Technicians is essential. Ford and Motorcraft parts are made to the same As you read through this manual, you will come across exacting standards as the original factory fitted WARNINGS, CAUTIONS and NOTES. No Skin contact may result in frostbite.In the molten state they may cause burns and health hazards may arise Splashes entering the eye will cause discomfort and from the inhalation of toxic fumes.Ford original production and precaution warnings given on material containers replacement items for this model are asbestos free. Make sure that electrical equipment is maintained in Ford supports worldwide elimination of CFC usage good condition and frequently tested. Faulty and it is recommended that Company subsidiaries and E850 EN. These may be immediate or delayed. Fluoroelastomer Diesel engine See Viton. Soot, discomfort and irritation usually give adequate warning of hazardous fume concentrations.Gaskets (Fluoroelastomer) See Viton.See Asbestos in this subsection. 1. Components or assemblies displaying the caution. Always disconnect the jumper cables in the reverse order to the connecting sequence and do not short the ends of the cables.This means working others.Also, any non-standard tyre notes to recall important findings later.CARRY OUT Pinpoint Test E. INSTALL new front wheel halfshaft joint boot(s). REFER to Section 205-04. TEST the system for normal operation.REFER to Pinpoint Test D, Engine Accessory Vibration. INSTALL new components as necessary. ALIGN the powertrain. TEST the system normal operation.GO TO D2 CARRY OUT the stall test with the brakes locked (load the engine by slipping the clutch in gear).GO TO D5 Diagnose the accessory drive belt concern. REFER to Section 303-05.GO TO E2 INSTALL new bearings as necessary.TEST the system for normal operation.

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• boone and crockett clubs complete guide to hunting whitetails deer hunting tips guaranteed to improv.

CHECK the rear brakes. GO TO F5 CHECK the front brakes. REFER to Section 206-03.GO TO F8 Condition corrected.GO TO H2 CARRY OUT the setup procedures again.GO TO I3 INSTALL a new tensioner. REFER to Section 303-05. TEST the system for normal operation.INSTALL a new belt. TEST the system for normal operation. If the condition still occurs after installation GO to Pinpoint Test C. REFER to Section 303-00.Retighten the engine insulator mounting bolts.REFER to Section 204-01.INSTALL new or REPAIR worn or damaged components as necessary. TEST the system for normal operation.INSTALL new or REPAIR worn components. REFER to Section 211-00.GO to Pinpoint Test D. INSPECT the rear suspension components for wear or damage. INSTALL new or REPAIR worn or damaged components as necessary. REFER to Section 204-02. TEST the system for normal operation.INSTALL new springs. REFER to Section 204-01. (front) REFER to Section 204-02. (rear). TEST the system for normal operation.INSTALL new tyres. CHECK the wheel alignment. TEST the system for normal operation.INSTALL new tyres. TEST the system for normal operation.GO TO G11 INSTALL a new rear hub. REFER to Section 204-02. TEST the system for normal operation.TEST the system for normal operation. G12: WHEEL BALANCE 1 Balance all the wheels. REFER to Section 100-04. Verify the customer concern.There should be no endplay. If endplay exists, install new wheel bearings.For additional information, refer to Section 206-03.Using the special tools, remove the wheel hub from the wheel knuckle.For additional information, refer to Wheel Knuckle in this section.For additional information, refer to Section 204-03.Installation 1. Install the wheel knuckle to the suspension unit. CAUTION: Make sure the halfshaft is completely installed into the wheel hub. Using the special tool, install the halfshaft into the wheel hub.Failure to follow this instruction may result in personal injury.Installation 1. Install the new ball joint. 2. Install the lower arm.

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Refer to the procedure in this section. 3. Check the front wheel alignment. For additional information, refer to Section 204-00.Detach the caliper and anchor plate assembly.CAUTION: Use an Allen key to prevent the piston rod from rotating.Install the suspension unit top mount nut. 3. Install the wheel knuckle to the suspension unit. 1. Install the special tool and rotate through 90 degrees. 2. Install the wheel knuckle.For additional information, refer to Section 204-00.Failure to follow this instruction may result in personal injury. Partially compress the spring.To assemble, reverse the disassembly procedure.The bump rubbers mounted on top of the axle tube limit the vertical movement.Remove the nut and bolt from both the rear spring eyes, slacken the upper shackle nut and lower the spring.Tighten the upper shackle nut (s). Refit two bolts on each side of the shock absorber upper mounting plates.For additional information, refer to Section 206-05. 9. Adjust the Load Active Valve (LAV).NOTE: Support the brake carrier assembly to prevent damage to the brake flexible hoses.Refer to Section 204-02-17 7. Adjust Load apportioning valve (LAV).Refer to Section 204-02-17. 6. Adjust the Load Active Valve (LAV).Installation 1. Install the new shock absorbers in reverse order.WARNING: Retighten the wheel nuts at 800 Km after any wheel change or anytime the wheel nuts are loosened.Do not exceed the maximum speed specified by the tyre manufacturer. When using winter tyres, the tyre pressures supplied by the tyre manufacturer must be adhered to.Clean the wheel hub and mounting surfaces. 2. Install the wheel and tyre assembly. 3. Lower the vehicle. 4. Tighten the wheel nuts in a diagonally opposed pattern.Foreign matter on the the exhaust system.Undo the suspension strut top nut by five turns. 2. Loosen the axle stub nut. 3. Detach the front wheel. For additional information, refer to Section 204-03.Undo the suspension strut top nut by five turns. 2. Loosen the axle stub nut. 3.

Detach the front wheel. For additional information, refer to Section 204-03.Mark the nut. CAUTION: Do not tighten the axle stub nut yet.For additional information, refer to Section 204-03. 7. Tighten the axle stub nut. 8. NOTE: Use an Allen key to stop the piston rod from turning. Tighten the suspension strut top nut.Undo the suspension strut top nut by five turns. 2. Raise the vehicle. For additional information, refer to Section 100-02. 3. Detach the lower suspension arm from the spindle carrier.The inner joint must not be bent at more than 18 degrees. The outer joint must not be bent at more than 45 degrees. Assemble the left-hand front drive halfshaft tripod joint using high-durability grease.Tighten the suspension strut top nut.Loosen the suspension strut top nut by five turns. 2. Raise the vehicle. For additional information, refer to Section 100-02. 3. Detach the lower suspension arm from the spindle carrier.Tighten the suspension strut top nut.For additional information, refer to Section 100-02.Tighten the left-hand and the right-hand side strut and spring assembly upper retaining nut.Push back the boot. CAUTION: Constant velocity rollers can drop out.The brakes self adjust rear axle. The LAV control the hydraulic pressure during foot brake operation.INSTALL new brake shoes or brake pads. TEST the system for normal operation.REPAIR as necessary. ADD fluid and BLEED the brake system. REFER to Section 206-00. TEST the system for normal operation.CHECK the rear brake drums for excessive wear. INSTALL new components as necessary. TEST the system for normal operation.REFER to Section 206-05. If the condition still exists. BLEED the brake system. REFER to Section 206-00. TEST the system for normal operation.REPAIR as necessary. ADD fluid and BLEED the brake system. REFER to Section 206-00. TEST the system for normal operation.CLEAN as necessary. TEST the system for normal operation.GO TO G3 SUBSTITUTE known good tyres. INFLATE to the correct pressure.

TEST the system for normal operation.GO TO I2 INSTALL a new brake booster. TEST the system for normal operation.INSTALL a new brake booster check valve. TEST the system for normal operation.Apply the brake pedal and listen for noise. GO TO K2 Vehicle OK.If may have washed off if the vehicle has been the fluid level drops and no external leak can be found, check for a brake master cylinder bore end seal leak.Start the engine. If the level in the reservoir will rise during brake vacuum system is operating, the brake pedal application and fall during release.Service such a leak by linings, incorrectly adjusted parking brake, or installing new seals.Failure to follow this instruction may result in the bleed nipple becoming seized. Repeat the procedure for the remaining brake lines.Ensure that the vale is not damaged. 6. Adjust the valve linkage.The total dial reading should not exceed the given specification. For additional information, refer to Specification.For additional information, refer to Section 206-03 refer to Section 206-04.For additional information, refer to Section 100-02. 5. Remove the wheel. CAUTION: If the grease cap is damaged during removal install a new cap. Remove the grease cap. 7. Loosen the drum-retaining nut.For additional information, refer to Section 206-05.Detach the brake shoes from the wheel cylinder pistons. 5. Detach the brake shoes from the abutment bracket.Connect the brake shoes to the wheel cylinder. 8. Attach the brake shoes to the abutment block. 9. Install the hold down springs.Install the brake drum, wheel spindle and wheel hub assembly. 11. Adjust the parking brake cable.Installation NOTE: Make sure a gasket is installed between the wheel cylinder and back plate.For additional information, refer to Section 206-00.Installation 1. To install, reverse the removal procedure.CAUTION: Make sure the disc faces are clean and free from grease, dirt or rust prior to assembly. 2. Install the brake pads.

For additional information, refer to Section 204-03. 6. Depress the brake pedal, check the fluid level in the brake fluid reservoir and top up if necessary with brake fluid.Installation 1. To install, reverse the removal procedure. 2. Bleed the brake system. For additional information, refer to Section 206-00.Apply compressed air through the brake hose housing to remove the brake caliper piston.NOTE: Lubricate the piston, piston bore and pis- ton seal with Super DOT 4 brake fluid prior to installation. 1. To assemble, reverse the disassembly procedure.Clean the wheel hub and mounting surfaces. 2. Install the wheel and tyre assembly. 3. Lower the vehicle. 4. Tighten the wheel nuts in a diagonally opposed pattern.GO TO A3 INSTALL new brake shoes. REFER to Section 206-02. TEST the system for normal operation.CHECK for other causes such as conventional brake system components. REPAIR or INSTALL new components as necessary. REFER to Section 206-00.CHECK for other causes such as conven- tional brake system components. REPAIR or INSTALL new components as necessary. REFER to Section 206-00.Installation 1. To install, reverse the removal procedure. 2. Adjust the parking brake cable.For additional information, refer to Section 206-02. 12. Detach the parking brake cable. 1. Pull the secondary brake shoe lever backwards. 2. Disconnect the cable from the secondary brake shoe.For additional information, refer to Parking Brake Control in this section 2. Remove the switch. Installation 1. To install, reverse the removal procedure.CAUTION: Cap the clutch master cylinder hose to prevent fluid loss or dirt ingress. Disconnect the clutch master cylinder hose from the brake fluid reservoir.For additional information, refer to Section 206-00.Clutch pedal travel measurement must be 56.0 mm To install, reverse the removal procedure.CAUTION: Cap the clutch master cylinder hose to prevent fluid loss or dirt ingress. Disconnect the clutch master cylinder hose from the brake fluid reservoir.

Installation 1. To install, reverse the removal procedure. 2. Bleed the brake system. For additional information, refer to Section 206-00.Remove the brake pedal and bracket Installation 1. To install, reverse the removal procedure.The steering column cannot be repaired, install a new steering column.Fill the reservoir to the MAX mark is necessary.Fill up as necessary.If excessive noise is apparent, repeat the bleed procedure. 8. If the noise level is still unacceptable, leave the vehicle standing overnight then repeat the bleed procedure.Refer to the Wiring Diagram Section 700-06 for schematic and electrical information.For additional information, refer to Section 100- 02. 11. Remove the blanking cap from the power steering fluid cooler return line and connect the line from the power steering gear.All vehicles 15. Fill and bleed the power steering system.Vehicles with diesel engine 4. Disconnect the fuel injection pump electrical connector. 1. Pull out the locking handle. 2. Disconnect the electrical connector.All except vehicles with diesel engine 9. Connect the CKP electrical connector. Refer to the Wiring Diagram Section 700-06 for schematic and electrical information.For additional information, refer to Power Steering System Bleeding in this section 12.Vehicles with manual transaxle 8. Disconnect the gearshift linkage. 9. Remove the roll restrictor to transmission retaining bolt.Remove the steering gear. Installation 1. Install the steering gear. 2. Install the crossmember. 3. Install the roll restrictor.Install the upper steering coupling pinch bolt.The power idle speed.The relay then closes and the pump starts to operate.Allow the fluid to drain into a suitable container.For additional information, refer to Section 211-00.Using the special tool, remove the power steering pump pulley. E6613 EN 2002 Bantam. E6613 EN 2002 Bantam. For additional information, refer to Section 211-02. E6613 EN 2002 Bantam. E6614 EN 2002 Bantam. E6614 EN 2002 Bantam.

For additional information, refer to Section 303-05. 7. Fill and bleed the power steering system.For additional information, E6614 EN 2002 Bantam. Vehicles with manual transaxle 7. Disconnect the gearshift linkage. 8. Detach the gearshift control assembly and secure to one side.Remove the steering gear. 1. Ease the steering gear to the right. 2. Ease the steering gear out towards the rear.For additional information, refer to Section 308-06.CAUTION: Make sure no particles of the seal enter the steering gear. Drive a hole into the dust cap approximately 3 mm from the outer edge.Installation 1. Refit the components in the reverse order. 2. Bleed the power steering system (refer to procedure contained in this section).For additional information, refer to Section 100- 02.All Vehicles 12. Remove the rear support insulator to transmission bolt. All Vehicles 14. Using a suitable Transmission jack support the crossmember.Left-hand drive vehicles 22. Detach the power steering high-pressure line support brackets.All Vehicles 7. Install the power steering pump high- pressure line to the accessory drive belt lower guard.All Vehicles 11. Install the power steering gear floor seal.Vehicles with manual transaxle 10. Detach the shift rod and gearshift stabilizer. 1. Shift rod. 2. Gearshift stabilizer.Remove the bolts. 17. Remove the power steering gear to floor seal.All Vehicles 5. Connect the power steering fluid cooler to the power steering gear return line. 6. Install the power steering gear to floor seal.Tighten the exhaust front pipe flange joint nuts.For additional information, refer to Section 211-00.Detach the tie rod end from the wheel knuckle. 1. Release the tie rod end. 2. Remove the retaining nut.For additional information, refer to Section 204-00.Remove the steering gear boot. 1. Disconnect the breather pipe. 2. Slide the boot off the tie rod. Installation 1. To install, reverse the removal procedure.CAUTION: Make sure the steering is in the straight ahead position.

To install, reverse the removal procedure.Installation CAUTION: Make sure the steering is in the straight ahead position. To install, reverse the removal procedure.The ignition switch lock cylinder also controls the mechanism, which provides a positive lock for the steering column.GO TO A2 CLEAN and SECURE the ignition switch connector as required. TEST the system for normal operation.TEST the system for normal operation.TEST the system for normal operation. REPAIR circuit 75 (YE). TEST the system for normal operation.GO TO C4 INSTALL a new ignition switch. TEST the system for normal operation.TEST the system for normal operation.TEST the system for normal operation. REPAIR circuit 15 (GN). TEST the system for normal operation.GO TO D4 INSTALL a new ignition switch. TEST the system for normal operation.GO TO D7 REPAIR circuit 30 (RD). TEST the system for normal operation.VERIFY the customer concern. REFER to Section 501-16 to diagnose the wipers and washers.Installation 1. To install, reverse the removal procedure.Minor pitting is acceptable outside the active area.To determine the piston ring clearance, insert the Feeler Gauge right to the back of the groove, behind the wear ridge. Using the Feeler Gauge, measure the piston ring clearance.The difference is the connecting rod bore out-of-round. Verify the out-of-round and the bearing bore is within specification.Hydraulic lash adjuster This has the advantage of lowering friction and Cylinder head therefore increasing durability.Assembly guide NOTE: The sealing lip must be free of oil.Cylinder head gasket NOTE: Always use a new gasket when installing Guide dowels the cylinder head.NOTE: Always use a new gasket when installing the oil pan.The timing mark is stamped into the Tensioner arm (exhaust side) face of the sprocket.Disconnect the fuel lines. 4. Disconnect the accelerator cable. 1. Remove the clip and pull cable from the retaining bracket. 2. Disconnect the inner cable.

For additional information, refer to Section 100- 02. 8. Remove the engine undershield. 9. Remove the intake manifold lower retaining bolts (shown with the engine removed).Install the intake manifold. 2. Raise and support the vehicle. For refer to Section 100- 02.For additional information, refer to Section 100-02. 3. Remove the accessory drive belt cover.Installation 1. NOTE: The valve seals are fully installed by the pressure of the valve springs. Using the special tool, install the valve seals.For additional information, refer to Camshaft in this section. 7. Install the spark plugs. 8. Install the valve cover. For additional information, refer to Valve Cover in this section.Set the engine to TDC on cylinder No. 1. and wire together the chain and sprocket. 3. Remove the timing chain hydraulic tensioner.For additional information, refer to Valve cover in this section.Set the engine to TDC on cylinder No. 1. 5. Remove the timing chain hydraulic tensioner.NOTE: The crankshaft sprocket timing mark must be in the 6 o'clock position. Install the crankshaft sprocket and the timing chain.Install the timing chain onto the camshaft sprocket. 5. Using the special tool, tighten the camshaft sprocket retaining bolt. 6. Install the timing chain hydraulic tensioner.For additional information, refer to Valve Cover in this section. 8. Install the oil pump. For additional information, refer to Oil Pump in this section.NOTE: The sealing lip must be free of oil. NOTE: Make sure the aligning dowels are located. Install a new rear oil seal retainer.For additional information, refer to Oil Pan in this section. 3. Install the flywheel. 4. Install the clutch. For additional information, refer to Section 308-01. 5. Install the transaxle. For additional information, refer to Section 308-03.Pull off the spark plug connector. 6. Remove the electronic ignition (EI) coil and position it to one side.Installation 1. NOTE: Use a new gasket. Install the exhaust manifold. 2.

Install the upper heat shield.WARNING: Escaping fuel. Observe the safety regulations for working with fuel. Disconnect the fuel lines.For additional information, refer to Section 100-02. 11. Remove the engine undershield. 12. Remove the lower intake manifold bolts (engine shown removed for clarity).Set the engine to TDC on cylinder No. 1. 17. Remove the timing chain hydraulic tensioner.Tighten the oil level indicator tube bolt. 7. Install the timing chain hydraulic tensioner.For additional information, refer to Section 303-03. 23. Connect the battery ground cable.For additional information, refer to Section 100- 02.For refer to Section 308- 01.Install the transaxle. For additional information, refer to Section 308-03. 12. Fill the engine with low friction oil meeting SAE 15W40 SH specification.For additional information, refer to Front Oil Seal in this section 3. Install the oil pan. For additional information, refer to Oil Pan in this section.WARNING: Danger of scalding if the engine is warm.Vehicles with 1.3L engine. 14. Remove the knock sensor. Note: Inlet manifold removed for clarity. All vehicles. 15. Disconnect the reversing lamp switch electrical connector.For additional information, refer to Section 100- 02. 23. Remove the engine undershield. 24. Remove the accessory drive belt cover.Remove the engine roll restrictor.Remove the starter motor and the transaxle left-hand flange bolt.Remove the transaxle right-hand flange bolts. 44. Remove the transaxle lower flange bolts. 45. Remove the transaxle upper flange bolt. 46. Separate the transaxle from the engine.Remove the spark plugs.Remove the valve cover. 16. Remove the crankshaft position (CKP) sensor and the oil pressure switch. 17. Remove the oil filter. 18. Remove the coolant flow control housing.Using the special tool, remove the cylinder head. 1. Remove the cylinder head bolts. 2. Remove and discard the gasket.Remove the water pump pulley. 24. Remove the water pump. 25. Remove the crankshaft pulley. 26.

Remove the flywheel.Remove the crankshaft. 1. Remove the main bearing caps. 2. Remove the crankshaft. 3. Remove the bearing shells and thrust washers. Keep all parts in order for reassembly.Remove the roller finger cam followers.Install the coolant flow control housing. 11. Install the exhaust manifold with a new gasket. 12. Install the exhaust heat shield.For additional information, refer to Section 303-00. 3. Measure the cylinder bore. For additional information, refer to Section 303-00. 4. Measure the pistons. For additional information, refer to Section 303-00.Install the oil pan baffle.Install the oil pump screen and pick up tube.Install the coolant flow control housing.Vehicles with 1.3L engine. 35. Install the knock sensor. Note: intake manifold removed for clarity.Install the intake manifold. 39. Connect the camshaft position (CMP) sensor and engine coolant temperature (ECT) sensor electrical connectors.Install the vacuum hoses. 41. Install the generator bracket. 42. Install the generator. 43. Install the engine mounting bracket.Install the special tool. 45. Secure the engine to the assembly table with retaining straps. 46. Install the exhaust manifold with a new gasket.For additional information, refer to Section 100- 02. 8. Secure the engine and transmission assembly with a retaining strap to the assembly stand and position for installation underneath the vehicle.Connect the clutch slave cylinder hydraulic line. 13. Remove the retaining straps from the engine. 14. Raise and support the vehicle. For refer to Section 100- 02.Install both front drive halfshafts. 18. Connect the lower arms to the wheel knuckles on both sides (left-hand side shown).Vehicles with air conditioning 22.Tighten the suspension strut retaining nut on both sides (right-hand side shown).Install the cooling fan. 29. Connect the cooling fan electrical connectors. 30. Connect the speedometer drive cable to the transaxle. 31. Connect the reversing lamp switch electrical connector.

Install the air cleaner intake pipe.For additional information, refer to Section 303-03. 48. Adjust the gearshift linkage. For additional information, refer to Section 308-06. 49. Bleed the clutch system. For additional information, refer to Section 308-00.Remove the timing belt. 23. Raise the vehicle. 24. Remove the flange of the crankshaft front timing pulley. 25. Remove the crankshaft rear timing pulley.Check the alignment of the front plate.NOTE: Coat the contact face of the bolt head with engine oil.Take out the timing pins. 4. Fit the blanking plug.First tighten the bolt on the pulley side, then the rear upper long bolt and finally the rear lower short bolt. Install the alternator and connect it.Lower the engine with the engine support bar. 24. Fit the upper timing belt cover. 25. Fit the front engine mounting bracket.For additional information, refer to Section 303-03.Detach the engine support bar. 6. Slacken the flange bolt of the camshaft timing pulley. 7. Remove the camshaft timing pulley. 8. Detach the crankcase ventilation hose.Installation CAUTION: Cover the grooves in the valve stems with installation sleeves. NOTE: Remove the installation sleeves after installation. Lubricate the new valve stem seals with engine oil and fit them.Release the camshaft timing belt pulley from its conical seat by tapping lightly with a light metal drift.Tighten the camshaft pulley bolt finger tight and then undo it a quarter turn.NOTE: Before fitting the gasket, coat it lightly with engine oil. Fit the cylinder head cover. 1. Screw in the bolts. 2. Attach the PCV hoses.Install the alternator and connect it. 5. Fit the belt tensioner.Detach the engine support bar.Detach the engine support bar. 4. Slacken the flange bolt of the camshaft timing pulley.WARNING: The timing belt tensioner is spring-loaded.Detach the vacuum pump oil return hose.Fit the cylinder head cover. 1. Tighten the bolts. 2. Attach the crankcase ventilation hoses. 9.

Attach the catalytic converter to the exhaust manifold.Attach the coolant hoses to the thermostat housing.Fit the camshaft timing belt pulley. 23. Attach the coolant hose. 24. Connect the battery negative lead.Slacken the nuts on the two suspension struts five turns each.Detach the brake servo vacuum line. 14. Disconnect the plug of the exhaust gas re- circulation valve (EGR valve).Detach the power steering hose and pressure pipe. 21. Remove the belt tensioner. 22. Remove the front engine mounting auxiliary bracket.Detach the air conditioning condenser at the bottom and tie up.Remove the front driveshaft center bearing.Remove the resonator. 54. Remove the starter motor. 55. Unscrew the front flange bolts. 56. Unscrew the rear flange bolts.Detach the oil pump with the oil filter.WARNING: The timing belt tensioner is spring-loaded.Remove the engine mounting bracket. 19. Remove the timing belt side cover. 20. Remove the oil dipstick tube.Detach the hose. 22. Remove the fuel feed line. 23. Disconnect the injection pipes and leak-off hoses. 24. Remove the injection pump bracket. 25. Remove the injection pump.Remove the clutch. 39. Remove the flywheel. 40. Remove the crankshaft position sensor (CKP). 41. NOTE: The oil seal is integrated in the housing. Remove crankshaft rear oil seal housing.Remove the flange bolt of the camshaft timing belt pulley.Fit the flange of the camshaft timing belt pulley. Insert the Woodruff key. 1. Fit the flange. 2. Draw the flange on with the bolt and tighten the bolt.Fit the timing belt pulley. 23. Fit the oil pressure switch. 24. NOTE: Tightening sequence. NOTE: Plastic sleeve on the right-hand upper stud (no. 7). Fit the exhaust manifold with a new gasket.When measured in the cylinder, the values can be exceeded by 0,15 mm.NOTE: Do not oil the cylinder head bolts. Fit the cylinder head and tighten the new cylinder head bolts in two stages.NOTE: The bolts must not be at the ends of their slots. 3.

Tighten the bolts of the timing belt pulley.CAUTION: Remove the special tools. Turn the crankshaft six turns in the normal direction of rotation of the engine.Engines with automatic timing belt tensioner 67. NOTE: If necessary, turn the camshaft using water pump pliers until the timing tool can be inserted. Insert the special tool in the camshaft.CAUTION: Remove the special tools. Turn the crankshaft four turns in the normal direction of rotation of the engine.Unscrew the timing pin and tighten the blanking plug for the TDC setting bore.Fit the cylinder head cover. 1. Screw in the bolts. 2. Attach the crankcase ventilation hoses. 77. Fit the injection pump timing belt cover.Install the oil pump with the oil filter.Detach the engine from the assembly stand.Install the starter motor.NOTE: Do not tighten the nuts and bolts. 1. Bolts 2. Nuts 3. Fit the transmission breather.Install the right-hand driveshaft, together with the intermediate shaft, in the transmission.Attach the speedometer drive cable. 33. Connect the generator. 34. Connect the starter motor. 35. Connect the plug of the multi-function switch (where fitted).Connect the bottom right-hand coolant hose to the radiator. 45. Connect the bottom coolant hose. 46. Lower the vehicle. 47. Attach the front engine mounting auxiliary bracket.Attach the brake servo vacuum line. 57. Connect the plug of the EGR valve.For additional information, refer to Section 303-03. 2. Remove the cylinder head cover. 1. Detach the crankcase ventilation hoses. 2. Remove the screws. 3. Remove the oil baffle.NOTE: Before fitting the gasket, coat it lightly with engine oil. Fit the cylinder head cover. 1. Screw in the bolts. 2. Attach the crankcase ventilation hoses.Component Tests 4. If the concern is not visually evident, verify the symptom and refer to WDS.Refer to the procedure in this section. 2. Disconnect the coolant hose. 3. Remove the thermostat housing. 4. Remove the thermostat.Refer to the procedure in this section.