
19FUEL SYSTEM
2
DESCRIPTION AND OPERATION A mechanical lift pump, with a hand priming facility, is
driven by the camshaft, and is mounted on the RH
side of the engine.
A fuel filter, with a replaceable element and
incorporating a water separator, is mounted on the
front RH side of the engine compartment.
A fuel sedimentor may be fitted when the vehicle is
operating in more arduous conditions, and is used to
minimise water deposits in the fuel system before
reaching the fuel pump and filter.
Fuel injection is carried out by a Bosch direct injection
pump, incorporating a cold start advance unit and a
high idle setting. The pump is mounted on the RH side
of the engine and is driven directly by gears in the
front cover from the crankshaft. The pump meters and
distributes fuel to 4 pintle type injectors located in
pre-combustion chambers in the cylinder head. Four
heater plugs, located in the cylinder head directly
below each injector, are fitted to improve cold starting.
An optional hand throttle, for use with a centre power
take off, is located on the fascia to the LH side of the
fuse box, and is linked independently to the fuel
injection pump throttle lever.
Air intake
The air cleaner is mounted on the RH side of the
engine and is connected by hoses to the cold air
intake duct and turbocharger inlet. Fitted between the
air cleaner and turbocharger is the crankcase breather
hose which connects to a breather filter on the rocker
cover.
A single stage turbocharger, fitted between the
exhaust manifold and exhaust down pipe, is
connected by hoses to the air cleaner and an
intercooler which is mounted on the LH side of the
radiator. The intercooler is connected by a hose to the
inlet manifold. When an EGR valve is fitted to the
turbocharger, additional pipes/hoses are used to
connect the components.Exhaust gas recirculation (EGR), when fitted.
Exhaust gas recirculation is controlled by an ECU
mounted under the front centre seat or cubby box and
receives the following inputs:
·Engine temperature from coolant temperature
sender unit on LH side of cylinder head.
·Throttle position from potentiometer on injection
pump.
·Engine speed from speedometer.
When all correct signals are received, the EGR
solenoid allows vacuum to open EGR valve and
recirculate a portion of the exhaust gas. See J6196 for
the EGR system component location and 'Operation'
for full system function.

FUEL SYSTEM
11
REPAIR HEATER PLUGS
Service repair no - 19.60.31
Remove
1.Disconnect battery.
No.1 heater plug - air conditioning models:
2.Release drive belt from compressor pulley.See
AIR CONDITIONING, Repair, Compressor
drive belt
3.Remove 4 bolts securing compressor to front
cover, move compressor aside.
No.3 heater plug:
4.Remove retaining bolt and withdraw breather
valve from rocker cover. Remove and discard 'O'
ring.
All heater plugs:
5.Remove terminal nut and disconnect wire from
heater plug terminal.
6.Unscrew heater plug.
Refit
7.Clean heater plug and seating.
8.Coat threads of heater plug with suitable
anti-seize compound operational to a
temperature of 1000°C.
9.Fit heater plug, tighten to
23 Nm (17 lbf/ft).
10.Connect wire to heater plug terminal and secure
with nut.
NOTE: Feed wire must be connected to
No. 4 heater plug terminal.
No. 3 heater plug:
11.Lubricate new 'O' ring with engine oil and fit to
breather valve.
12.Fit valve to rocker cover, tighten to bolt to
15 Nm
(11 lbf/ft).
No. 1 heater plug - air conditioning models
13.Position compressor to front cover, fit bolts and
tighten to
25 Nm (18 lbf/ft).
14.Fit drive belt to compressor pulley and adjust
tension.
See AIR CONDITIONING, Repair,
Compressor drive belt
All models:
15.Reconnect battery.

19FUEL SYSTEM
16
REPAIR INTERCOOLER
Service repair no - 19.42.15
Remove
1.Disconnect battery.
2.Remove 2 nuts securing fan cowl to radiator top
cover.
3.Remove 4 bolts securing radiator top cover to
side covers.
4.Remove 2 bolts from both sides, securing
radiator top cover mounting brackets to bonnet
platform.
5.Detach radiator top cover, complete with
mounting brackets.
6.Slacken retaining clip and disconnect top hose
from intercooler.
7.Slacken 2 clips and disconnect bottom hose
from intercooler.
8.Manoeuvre intercooler upwards and remove
from vehicle.
9.Check condition of foam pads fitted to top and
bottom of intercooler and renew if necessary.
10.Check condition of intercooler locating grommets
in radiator top cover and renew if necessary.
Refit
11.Manoeuvre intercooler into position at LH side of
radiator.
12.Carefully lower intercooler and locate bottom
lugs into radiator bottom support frame.
13.Fit bottom and top hoses to intercooler.
14.Fit radiator top cover and secure mounting
brackets to bonnet platform.
15.Secure radiator top cover to side covers.
16.Fit fan cowl to top cover.
17.Reconnect battery.

COOLING SYSTEM
3
DESCRIPTION AND OPERATION COOLANT CIRCULATION
Operation
When the engine is started from cold the thermostat
(2) prevents coolant circulation through the radiator by
closing off the top hose (6). During the engine warm
up period the water pump (5) circulates coolant to the
cylinders in the crankcase and through separate ports
to the cylinder head. At the rear of the cylinder head a
proportion of the flow is diverted through a heater feed
pipe (16) to the matrix of the heater unit (15). The
coolant is then carried, via a heater return rail (14) and
hoses (7), back to the water pump. The remaining
coolant flows through a by-pass hose (9) at the
thermostat housing and back to the water pump to
complete the first cycle.
When the normal engine running temperature is
reached, the thermostat opens, closing off the by-pass
hose (9). Coolant is then circulated via the top hose
(6) and through the radiator, where it is cooled and
drawn from the radiator bottom hose (3) by the water
pump (5). The coolant circulation through the
crankcase and cylinder head remains the same.
Two bleed pipes (10) and (11) help control the system
pressure by purging excess air and coolant to the
expansion tank via the 'Y'piece ejector (12).VISCOUS FAN
Description
The viscous drive unit for the engine cooling fan,
provides a means of controlling the speed of the fan
relative to the running temperature of the engine. The
viscous unit is a type of fluid coupling, which drives
the fan blades by means of 'silicone fluid'.
1.Input (drive) member
2.Output (driven) member
3.Sensing mechanism (bi-metal coil)
The fan drive has to be engaged only periodically,
between 5% and 10%, during normal operating
conditions, because the engine is cooled by ram air
for most of the time.

26COOLING SYSTEM
4
DESCRIPTION AND OPERATION Operation
To engage and disengage the fan drive the bi-metal
coil senses air temperature behind the radiator. When
a pre-determined temperature is reached, the coil
opens a valve (5) which allows fluid to enter the drive
area and, due to centrifugal force, circulates to the
annular drive area.
There are two sets of annular grooves (3), one in the
drive clutch and the other in the drive body, a specific
clearance being provided between the two sets of
grooves.
Viscous unit disengaged (engine at normal
running temperature)
1.Input (drive) member
2.Output (driven) member
3.Running clearance
4.Pump plate
5.Valve (closed)
6.Sensing mechanism (bi-metal coil)
7.Fluid seal
8.Bearing, input member
9.Fluid chamber
10.Fluid reservoirWhen this clearance is filled with viscous fluid, a
shearing action, caused by the speed differential
between the two drive components, transmits torque
to the fan. The fluid is thrown to the outside of the unit
by centrifugal force from where it is recirculated to the
reservoir (10) via the pump plate (4) adjacent to the
drive member.
If the engine speed is increased the amount of slip will
also increase to limit the maximum fan speed.
When the air temperature from the radiator drops
sufficiently, the bi-metal coil closes the valve and
prevents fluid entering the drive area. The fluid that is
in the drive area will gradually pump out into the
reservoir (10) and the fan will return to an idle
condition.
Viscous unit engaged (hot running temperature)
Bi-metal coil (6) expanded, valve (5) open.

COOLING SYSTEM
1
REPAIR VISCOUS COUPLING AND FAN
Service repair no - 26.25.19 - Viscous coupling
Service repair no - 26.25.05 - Fan
Remove
NOTE: The viscous coupling has a LH
thread.
1.Disconnect battery.
2.Using special pulley restraining toolLRT-12-094
and special spannerLRT-12-093unscrew
viscous coupling from pulley hub adaptor thread.
3.Remove viscous coupling and fan from vehicle.
NOTE: If air conditioning is fitted, the fan
cowl will also need removing,
See Fan
cowl
, with the viscous fan unit.
4.If required, remove 4 screws and release
viscous unit from fan blade.
Refit
5.Fit viscous unit to fan blades.
6.If applicable, fit fan cowl.
See Fan cowl
7.Carefully position viscous coupling and fit onto
pulley hub adaptor thread.
8.Using special pulley retaining tool, spanner and
a suitable torque wrench, tighten assembly to
45
Nm (33 lbf/ft).

26COOLING SYSTEM
2
REPAIR FAN COWL
Service repair no - 26.25.11
Remove
1.Disconnect battery.
2.Drain coolant.
See Adjustment, Drain and
refill cooling system.
3.Slacken retaining clips and remove radiator top
hose.
4.Slacken retaining clip and remove top hose from
intercooler.
NOTE: On vehicles fitted with EGR system,
remove complete intercooler top hose
assembly.
5.Remove viscous coupling and fan
See Viscous coupling and fan.
6.Remove 2 nuts securing top of fan cowl.
7.Release expansion tank hose from clips at base
of fan cowl.
8.Lift and remove cowl .
NOTE: On vehicles fitted with air
conditioning, it will be necessary to
remove the cowl and viscous fan unit
together to enable clearance of the compressor.Refit
9.Position fan cowl.
10.Fit viscous fan unit.
See Viscous coupling
and fan
11.Fit expansion tank hose into fan cowl clips.
12.Secure top of fan cowl to radiator top cover.
13.Fit intercooler top hose.
14.Fit radiator top hose.
15.Refill cooling system.
See Adjustment, Drain
and refill cooling system
16.Reconnect battery.
FAN PULLEY
Service repair no - 26.25.04.
Remove
1.Disconnect battery.
2.Remove viscous fan unit.
See Viscous
coupling and fan
3.Remove drive belt.See ELECTRICAL, Repair,
Auxiliary drive belt
4.Unscrew 4 bolts and remove pulley from adaptor
boss.
Refit
5.Fit fan pulley to adaptor boss. Tighten bolts to
25
Nm (18 lbf/ft).
6.Fit drive belt.See ELECTRICAL, Repair,
Auxiliary drive belt
7.Fit viscous fan unit.See Viscous coupling
and fan
8.Reconnect battery.

26COOLING SYSTEM
6
REPAIR RADIATOR
Service repair no - 26.40.01
Remove
1.Disconnect radiator bottom hose and drain
cooling system.
See Adjustment, Drain and
refill cooling system
2.Disconnect radiator top hose.
3.Remove viscous fan unit.
See Viscous
coupling and fan
4.Remove fan cowl.See Fan cowl
5.Disconnect oil cooler pipes. Plug all connections
to prevent oil spillage and ingress of dirt.
6.Disconnect top and bottom intercooler hoses.
7.Disconnect bleed hose at radiator.
8.Remove 2 bolts from both sides securing
radiator mounting brackets to bonnet platform.
9.Lift and remove radiator/intercooler assembly
from vehicle.
10.Remove 2 bolts from both sides and detach
radiator top cover from side covers.
11.Lift and remove radiator from intercooler and RH
side frame.
12.Check condition of locating grommets in radiator
top cover and lower mounting bushes. Renew if
necessary.Refit
13.Position radiator between intercooler and RH
side frame.
14.Fit radiator top cover to side covers.
15.Lower radiator/intercooler assembly into
position.
16.Secure radiator mounting brackets to bonnet
platform.
17.Fit radiator bleed hose.
18.Fit top and bottom intercooler hoses.
19.Fit oil cooler pipes.
20.Fit fan cowl
See Fan cowl.
21.Fit viscous fan unit.
See Viscous coupling
and fan
22.Fit radiator top hose.
23.Fit radiator bottom hose and refill cooling
system.
See Adjustment, Drain and refill
cooling system