Dashboard continued

I couldn't be arsed to glue some wood to the bottom edge of the dash and shape it to the 19mm radius so instead i padded it with some foam, and covered it - non rigid material.........

Dashboard

Started work on the dash today just need to glue something to the bottom to give the 19mm radius for sva test - "The instrument panel lower edge within the specified zone must be rounded to a radius of not less than 19mm (5mm if covered with a non-rigid material)." - from sva manual.

Then cover it......

Torque settings

Torque settings for Suspension

Caliper bracket to upright: 45-50 ft/lbs

Disc to the Hub: 30-34 ft/lbs

Hub Nut: Pack grease into bearing. Torque this nut up to 27 ft/lbs of torque and check for full and free rotation of the hub, it should be quite difficult to turn at this point. Now slacken the nut off by 90 degrees. This gives the hub endfloat the required 0.001-0.005 inches of movement.

Torque settings for Zetec engine

Torque wrench settings Nm lbf ft
Crankshaft speed/position sensor:
Sensor-to-bracket screw .................................. 6 to 9 4 to 6
Bracket-to-cylinder block crankcase screw .................... 21 15
Ignition coil bracket-to-cylinder head screws ................ 21 15
Alternator mounting bolts .................................... 50 37
Starter motor mounting bolts ................................. 35 26
Camshaft position sensor screw ..............................18 to 23 13 to 17
Intake air temperature sensor ................................. 23 17
Oxygen sensor ............................................ 60 44

Exhaust Gas Recirculation (EGR) system components:
Valve-to-inlet manifold bolts ................................ 9 6
Pipe-to-ignition coil screws ................................. 10 7
Pulse-air system components:
Filter housing mounting bolt ................................ 47 35
Piping-to-exhaust manifold sleeve nuts ....................... 32 24
Auxiliary drivebelt cover fasteners ........................5 to 10 4 to 7
Auxiliary drivebelt automatic tensioner Torx screws 23 17
Engine oil drain plug ........................................ 25 18
Manual transmission filler/level plug ............................ 35 26
Radiator undershield screws .................................. 7 5
Spark plugs ............................................... 15 11

Cylinder head cover bolts:
Stage 1 ................................................ 2 1.5
Stage 2 ................................................ 7 5
Camshaft toothed pulley bolts ................................ 68 50

Camshaft bearing cap bolts:
Stage 1 ................................................ 10 7
Stage 2 ................................................ 19 14

Cylinder head bolts:
Stage 1 ................................................ 25 18
Stage 2 ................................................ 45 33
Stage 3 ................................................ Angle-tighten a further 105°

Timing belt cover fasteners:
Upper-to-middle (outer) cover bolts .......................... 4 3
Cover-to-cylinder head or block bolts ........................ 7 5
Cover studs-to-cylinder head or block ........................ 9 to 11 6.5 to 8
Timing belt tensioner bolt .................................... 38 28
Timing belt tensioner backplate locating peg ..................... 8 to 11 6 to 8
Timing belt tensioner spring retaining pin ........................ 10 7
Timing belt guide pulley bolts ................................. 35 to 40 26 to 30
Water pump pulley bolts ..................................... 10 7
Water pump bolts .......................................... See Chapter 3
Auxiliary drivebelt idler pulley ................................. 48 35
Inlet manifold nuts and bolts .................................. 18 13
Alternator mounting bracket-to-cylinder block bolts ............... 47 35

Cylinder head support plates:
Front plate Torx screws - to power steering pump/air conditioning
compressor mounting bracket and cylinder head ............... 47 35
Rear plate/engine lifting eye - to alternator mounting bracket
and cylinder head bolts .................................... 47 35
Front engine lifting eye bolt ................................... 16 12
Inlet and exhaust manifold studs-to-cylinder head ................ 10 maximum 7 maximum

Exhaust manifold heat shield bolts:
Shield-to-cylinder head .................................... 7 5
Shield/dipstick tube ....................................... 10 7
Shield/coolant pipe-to-manifold ............................. 23 17
Exhaust manifold nuts ....................................... 16 12
Air conditioning refrigerant pipe-to-exhaust manifold bolts .......... 10 7
Crankshaft pulley bolt ....................................... 108 to 115 80 to 85
Oil pump-to-cylinder block bolts .............................. 10 7
Oil pick-up pipe-to-pump screws .............................. 10 7
Oil baffle/pump pick-up pipe nuts ............................. 19 14
Oil filter adaptor-to-pump .................................... 18 to 25 13 to 18
Oil pressure warning light switch .............................. 27 20
Oil level sensor ............................................ 27 20
Sump bolts ............................................... 21 to 22 15 to 16
Coolant pipe-to-sump bolt ................................... 10 7
Flywheel/driveplate bolts .................................... 110 to 112 81 to 83
Crankshaft left-hand oil seal carrier bolts ........................ 22 16
Transmission-to-engine bolts ................................. 40 30

Engine/transmission front mounting:
Mounting bracket-to-transmission ........................... Not available
Mounting-to-subframe bolts/nuts - stage 1 .................... 10 7
Mounting-to-subframe bolts/nuts - stage 2 .................... 48 35
Mounting centre bolt ...................................... 120 89
Engine/manual transmission rear mounting:
Mounting bracket-to-transmission 12 mm fasteners ............. 78 to 84 58 to 62
Mounting bracket-to-transmission 10 mm fasteners ............. 48 35
Mounting-to-subframe bolts and nut - stage 1 .................. 10 7
Mounting-to-subframe bolts and nut - stage 2 .................. 48 35
Mounting centre bolt ...................................... 120 89

Engine/automatic transmission rear mounting:
Mounting bracket-to-transmission ........................... 48 to 49 35 to 36
Mounting-to-subframe bolts - stage 1 ........................ 10 7
Mounting-to-subframe bolts - stage 2 ........................ 48 35
Mounting centre bolt ...................................... 120 89

Engine/transmission left-hand mounting:
Bracket-to-transmission nuts ............................... 83 61
Mounting centre bolt ...................................... Not available
Mounting-to-body bolts ................................... Not available

Engine/transmission right-hand mounting:
Bracket-to-engine and mounting nuts ........................ 83 to 90 61 to 66
Mounting-to-body bolts ................................... 84 62

Main bearing cap bolts and nuts .............................. 80 59

Big-end bearing cap bolts:
Stage 1 ................................................ 18 13
Stage 2 ................................................ Angle-tighten a further 90°
Piston-cooling oil jet/blanking plug Torx screws .................. 10 7

Cylinder block and head oilway blanking plugs:
M6 x 10 ................................................ 8 to 11 6 to
M10 x 11.5 - in block ...................................... 24 17
1/4 PTF plug - in block .................................... 25 18
Power steering pump/air conditioning compressor mounting
bracket-to-cylinder block bolts ................................ 47 35
Exhaust manifold heat shield mounting bracket-to-cylinder
block bolts ................................................ 32 24

Crankcase breather system:
Oil separator-to-cylinder block bolts ......................... 10 7
Pipe-to-cylinder head bolt .................................. 23 17

Driveshaft support bearing bracket-to-cylinder block bolts .......... 48 35

Thermostat housing-to-cylinder head bolts ...................... 20 15
Water outlet-to-thermostat housing bolts ....................... 8 to 11 6 to 8
Coolant temperature sensor .................................. 23 17
Coolant temperature gauge sender ............................ 8 6
Water pump bolts .......................................... 18 13

Plenum chamber-to-inlet manifold fasteners ..................... 4 3
Throttle housing-to-inlet manifold screws ....................... 10 7
Idle speed control valve bolts ................................. 6 4
Fuel pressure regulator bolts ................................. 6 4
Fuel injector bolts .......................................... 6 4
Fuel rail-to-inlet manifold bolts ................................ 10 7
Fuel feed and return line threaded couplings at fuel rail ....24 to 30 17 to 22
All exhaust system nuts and bolts ............................. 40 to 45 30 to 33