Page 503 of 1007

STEERING
57-10 REPAIRS
14.Remove clips from PAS oil cooler.
Refit
1.Clean cooler mounting points.
2.Fit clips to PAS cooler.
3.Fit PAS oil cooler to vehicle.
4.Connect quick release pipe fitting.
5.Align PAS pipe bracket, fit bolt and tighten to 10
Nm (7 lbf.ft).
6.Fit bolt to clip securing PAS pipe to RH turret,
tighten to 10 Nm (7 lbf.ft).
7.Fit PAS reservoir to mounting bracket.
8.Clean PAS fluid reservoir around filler cap and
fluid level indicators.
9.Fit PAS return hose to reservoir and secure
clip.
10. Td4 models: Fit intercooler outlet hose and
tighten clips.
11. Td4 models: Fit intake duct to body and duct
assembly.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Ducting - intake assembly.
12. Td4 models: Fit engine oil dipstick.
13. Fit engine acoustic cover if fitted.
+ ENGINE - Td4, REPAIRS, Cover -
engine acoustic - Up to 02.5 Model Year.
14.Connect battery earth lead.
15.Bleed PAS system.
+ STEERING, ADJUSTMENTS, Power
assisted steering (PAS) system - bleed.
Oil cooler - KV6 models
$% 57.15.11
Remove
1.Remove front bumper.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
2.Position container below PAS pipes to catch
fluid spillage.
3.Using LRT-57-044 release and disconnect
PAS hoses from oil cooler.
4.Remove 2 bolts and remove PAS fluid cooler.
Refit
1.Fit fluid cooler and tighten bolts to 10 Nm (7
lbf.ft).
2.Clean connections.
3.Connect hoses to fluid cooler.
4.Fit front bumper.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5.Bleed PAS system.
+ STEERING, ADJUSTMENTS, Power
assisted steering (PAS) system - bleed.
M57 1204
LRT-57-044
Page 924 of 1007
CHARGING AND STARTING
REPAIRS 86-1-11
Tensioner - ancillary drive belt - Td4
$% 86.10.06
Remove
1.Disconnect battery earth lead.
2.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Remove hydramount.
+ ENGINE - Td4, REPAIRS,
Hydramount - engine - RH.
4.Remove ancillary drive belt.
+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - Td4.
5.Remove bolt securing dipstick tube to oil filter.
6.Move dipstick tube aside for access.
7.Remove alternator.
+ CHARGING AND STARTING,
REPAIRS, Alternator - Td4.
8.Manoeuvre engine to suitable working height.9.Remove Allen bolt securing ancillary belt idler
and remove idler from vehicle.
10.Remove nut, securing ancillary drive belt
tensioner arm to rear of spring housing.
11.Rotate belt tensioner arm through 180° to clear
chassis side member and remove from timing
cover.
M86 5302
M86 5303
Page 925 of 1007

CHARGING AND STARTING
86-1-12 REPAIRS
12.Remove and discard tensioner arm seal.
13.Remove 2 bolts from timing cover, securing
ancillary drive belt tensioner.
14.Remove tensioner.
Refit
1.Clean tensioner block and mounting.
2.Position tensioner block, temporarily fit
tensioner arm to align spring block with timing
cover. Fit bolts and tighten to 25 Nm (18 lbf.ft).
Remove tensioner arm.
3.Clean seal mounting for tensioner arm on
timing cover, fit new seal.
4.Fit ancillary drive belt tensioner arm to timing
cover, turn through 180° to align with tensioner
spring housing, push fully home. Fit and tighten
nut to 10 Nm (7.5 lbf.ft).
5.Fit alternator.
+ CHARGING AND STARTING,
REPAIRS, Alternator - Td4.
6.Fit idler pulley to mounting and tighten Allen
bolt to 25 Nm (18 lbf.ft).
7.Position dipstick tube to oil filter, fit bolt and
tighten to 10 Nm (7.5 lbf.ft).
8.Fit ancillary drive belt.
+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - Td4.
9.Fit hydramount.
+ ENGINE - Td4, REPAIRS,
Hydramount - engine - RH.
10.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
11.Connect battery earth lead.
Battery
$% 86.15.01
Remove
1.Disconnect both battery terminals, earth lead
first.
2.Remove bolt and battery clamp.
3.Remove battery.
Refit
1.Clean battery tray.
2.Fit battery and clamp, tighten bolt to 12 Nm (9
lbf.ft).
3.Apply petroleum jelly to both terminals, fit and
tighten terminal bolts negative lead last.
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