CHARGING AND STARTING
REPAIRS 86-1-1
CHARGING AND STARTING REPAIRS
Alternator - diesel
$% 86.10.02
Remove
1.Remove auxiliary drive belt.
+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Release cover and remove nut securing lead
to alternator.
3.Disconnect alternator multiplug.
4.Remove bolt (LH thread) and remove auxiliary
drive belt tensioner. 5.Remove bolt securing support stay to
alternator.
6.Release clip and disconnect oil drain hose from
vacuum pump.
7.Disconnect vacuum pump oil supply pipe from
cylinder head and discard 'O' ring.
8.Remove bolt securing alternator and release
from mounting bracket.
9.Disconnect vacuum hose from vacuum pump.
10.Remove alternator. Take care not to damage
radiator cooling fins.
11.Remove 4 bolts, and remove vacuum pump
from alternator.
CAUTION: Always fit plugs to open
connections to prevent contamination.
CHARGING AND STARTING
86-1-4 REPAIRS
Belt - auxiliary drive
$% 86.10.03
Remove
1.Remove viscous fan:
l
+ COOLING SYSTEM - V8,
REPAIRS, Fan - viscous.
l
+ COOLING SYSTEM - Td5,
REPAIRS, Fan - viscous.
2.Turn drive belt tensioner using a 15 mm ring
spanner and release belt from pulleys.
Refit
1.Clean drive belt pulley grooves and ensure
grooves are not damaged.
2.Fit new drive belt around pulleys, ensure belt is
correctly aligned in pulley grooves.
3.With assistance, hold tensioner fully clockwise
and fit drive belt around remaining pulley.
Release tensioner.
4.Fit viscous fan:
l
+ COOLING SYSTEM - Td5,
REPAIRS, Fan - viscous.
l
+ COOLING SYSTEM - V8,
REPAIRS, Fan - viscous.
Battery
$% 86.15.01
Remove
1.Release fixings and remove battery cover.
2.Disconnect both battery leads, negative lead
first.
3.Remove lock nuts and retaining nuts securing
battery clamp.
4.Remove battery clamp.
5.Remove battery.
Refit
1.Clean battery terminals and coat with
petroleum jelly.
2.Fit battery.
3.Fit battery clamp and tighten retaining nuts and
lock nuts.
4.Fit both battery leads, negative lead last.
5.Fit battery cover and secure fixings.
HARNESSES
86-7-16 REPAIRS
7.Disconnect multiplugs from receiver drier and
air temperature sensor.
8.Release 3 cable tie clips securing harness to
lower support rail. 9.Disconnect multiplugs from cooling fan and
horn.
10.Release 3 cable tie clips from front RH panel.
11.Remove RH indicator lamp.
+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.
HARNESSES
86-7-28 REPAIRS
50.Feed harness through to front panel.
51.Secure fog lamp multiplug.
52.Connect headlamp level motor, headlamp and
side lamp multiplugs.
53.Fit indicator lamp.
+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.
54.Secure harness to RH front panel.
55.Connect cooling fan and horn multiplug.
56.Secure harness to lower support rail.
57.Connect receiver drier and air temperature
sensor multiplugs.
58.Fit front bumper.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
59.Fit battery tray.
60.Fit air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
61.Position both lower 'A' post trims and secure
with studs.
62.Fit heater assembly.
+ HEATING AND VENTILATION,
REPAIRS, Heater assembly - models with
air conditioning.
+ HEATING AND VENTILATION,
REPAIRS, Heater assembly - models
without air conditioning.
Harness - main - DVD unit
$% 86.70.25
Remove
1.Remove battery cover and disconnect the
battery earth lead.
2.Remove CD switch box.
+ IN CAR ENTERTAINMENT,
REPAIRS, Switch box - CD/DVD player.
3.Remove DVD player unit.
+ IN CAR ENTERTAINMENT,
REPAIRS, DVD screen/player unit.
4.Release screw covers, remove 4 screws and
remove front and rear grab handles from
drivers side.
