Page 80 of 1672
GENERAL DATA
04-17
Air conditioning
Electrical - Td5
Electrical - V8
Type CFC free, sealed closed loop
Compressor:
Displacement 177.7 cm
3/rev (10.84 in3/rev)
Relief valve operating pressure 34.3 to 41.4 bar (497 to 600 lbf.in
2)
Refrigerant oil quantity 180ml (6.3 fl.oz)
Dual pressure switch operating pressures (nominal):
Low pressure switch Opens 2.0 bar (29.0 lbf.in
2), pressure decreasing
Low pressure switch Closes 2.3 bar (33.4 lbf.in
2), pressure increasing
High pressure switch Opens 32 bar (464 lbf.in
2), pressure increasing
High pressure switch Closes 26 bar (377 lbf.in
2), pressure decreasing
System 12 volt, negative earth
Battery:
Type Delco Freedom
Capacity 110 amp hour
Alternator:
Type Nippon Denso
Maximum output 120 amp
Starter motor:
Type Nippon Denso
Power 2 kW
System 12 volt, negative earth
Battery:
Type Delco Freedom
Capacity 72 amp hour
Alternator:
Type Bosch NC65/130
Maximum output 130 amp
Starter motor
Type Nippon Denso
Power 1.8 kW
Page 100 of 1672
TORQUE WRENCH SETTINGS
06-15
Heating and air conditioning
Wipers and washers
Electrical
TORQUE DESCRIPTION METRIC IMPERIAL
Heater assembly16 Nm (12 lbf.ft)
Compressor bolts 22 Nm (16 lbf.ft)
Blower motor19 Nm (14 lbf.ft)
Compressor to mounting bracket bolts 25 Nm (18 lbf.ft)
A/C pipes to compressor bolts 10 Nm (7 lbf.ft)
Condenser pipe bolt 5 Nm (3.7 lbf.ft)
Receiver drier to bracket bolts 5 Nm (3.7 lbf.ft)
Adaptor block to receiver drier bolt 5 Nm (3.7 lbf.ft)
Evaporator pipe bolts 5 Nm (3.7 lbf.ft)
Dual pressure switch to receiver drier 10 Nm (7 lbf.ft)
Air conditioning pipes to receiver drier bolts 5 Nm (3.7 lbf.ft)
TX valve pressure pipe union 22 Nm (16 lbf.ft)
Evaporator pipe to TXV valve 32 Nm (24 lbf.ft)
Evaporator assembly to body bolts 16 Nm (12 lbf.ft)
High and low pressure pipe, bolts 10 Nm (7 lbf.ft)
Fuel burning heater Torx bolts 25 Nm (18 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Link to motor spindle 7 Nm (5.2 lbf.ft)
Front motor assembly 2.5 Nm (1.8 lbf.ft)
Spindle nut 3 Nm (2.2 lbf.ft)
Wiper arm nut13 Nm (10 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Alternator support stay 25 Nm (18 lbf.ft)
Alternator lead - Td5 6 Nm (4.4 lbf.ft)
Auxiliary drive belt tensioner bolt 50 Nm (37 lbf.ft)
Alternator pulley80 Nm (59 lbf.ft)
Alternator B+ nut - V8 18 Nm (13 lbf.ft)
Alternator B+ nut - V8 5 Nm (3.7 lbf.ft)
Starter motor - Td5 27 Nm (20 lbf.ft)
Starter motor solenoid 10 Nm (7 lbf.ft)
Starter motor - V8 44 Nm (32 lbf.ft)
Alternator45 Nm (33 lbf.ft)
Starter motor heat shield - V8 10 Nm (7 lbf.ft)
Horn13 Nm (10 lbf.ft)
Battery carrier bolts 28 Nm (21 lbf.ft)
Page 107 of 1672
CAPACITIES, FLUIDS AND LUBRICANTS
09-2
Refrigerant - A/C system
Fluids
Anti-freeze
Use Havoline Extended Life Coolant (XLC), or any
ethylene glycol based anti-freeze (containing no
methanol) with only Organic Acid Technology
corrosion inhibitors, to protect the cooling system
CAUTION: No other anti-freeze should be used
with Havoline Extended Life Coolant.
The cooling system should be drained, flushed and
refilled with the correct amount of anti-freeze solution
at the intervals given on the Service Maintenance
Check Sheet.
After filling with anti-freeze solution, attach a warning
label to a prominent position on the vehicle stating
the type of anti-freeze contained in the cooling
system to ensure that the correct type is used for
topping-up.
Brake/Clutch fluid
Use only DOT 4 brake fluid.
PAS/ACE fluid
Use Texaco cold climate power assisted steering
fluid 14315.
Air conditioning
Use only refrigerant R134a.
Refrigerant oil
Use only NipponDenso ND-oil 8 or Unipart ND-oil 8.
Refrigerant oil absorbs water and must not be stored
for long periods. Do not pour unused oil back into the
container.
NOTE: The total quantity of refrigerant oil in the
system is 180 ml.
CAUTION: Do not use any other type of
refrigerant oil.
Refill3.4 pt
Fill from dry 3.6 pt
Cooling system - V8 Engine:
Refill24.2 pt
Fill from dry 26.2 ptComponent US Units
Front A/C 700 ± 25 g
Front/rear A/C 900 ± 25 g
Page 109 of 1672
CAPACITIES, FLUIDS AND LUBRICANTS
09-4
Engine oil - V8 - high compression engine
Use a 5W/30 oil meeting specification ACEA: A1,
(API SJ or ILSAC GF2 for USA).
NOTE: ACEA: A2 can be used.
Engine oil - Td5
Use oil meeting specification ACEA: A1, B1 or B2.
Gearbox oil
Use of gearbox oils other than those specified may
result in serious damage to the gearbox,
Manual Gearbox
Use Texaco MTF 94 oil for refill and topping-up. If
MTF 94 is not available, ATF Dexron IID or ATF
Dexron III may be used.
Automatic Gearbox
Use ATF Dexron IID or Dexron III oil for refill or
topping-up.
Transfer box
Use Texaco Multi-Gear 75W/90R.
Front and rear axles
Use Texaco Multi-Gear 75W/90R.
Air Conditioning
Use lubricating oil Nippon Denso ND-8.
General Greasing
Use Multipurpose Lithium Base Grease N.L.G.I.
consistency No. 2.
Bonnet latch
Lubricate cable and latch with oil.
Locks, Latches and Hinges
Use Door Lock and Latch Lubricant, Part No. VWN
10075.
Page 203 of 1672
ENGINE - TD5
12-1-64 REPAIRS
Refit
1.Clean oil cooler and mating faces.
2.Fit oil pressure switch and tighten to 9 Nm (7
lbf.ft).
3.Position new gasket and fit oil cooler housing,
tighten bolts to 25 Nm (18 lbf.ft).
4.Position and fit oil filter adaptor housing,
tighten bolts to 25 Nm (18 lbf. ft).
5.Fit oil filter, tighten hand tight then a further half
turn.
6.Position coolant hose to oil cooler and secure
clip.
7.Position coolant pipe bolt and tighten to 50 Nm
(37 lbf.ft) .
8.Connect multiplug to oil pressure switch.
9.Fit centrifuge assembly.
+ ENGINE - Td5, REPAIRS, Gasket -
centrifuge oil drain pipe.
10.Refill cooling system.
+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
11.Top up engine oil.
+ MAINTENANCE, PROCEDURES,
Engine oil - diesel engine.
Gasket - centrifuge oil drain pipe
$% 12.60.90
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove fixings and remove underbelly panel.
3.Remove 2 bolts securing centrifuge drain to
engine sump and discard gasket. (Some
models are fitted with studs and nuts,
others with bolts).
4.Remove turbocharger.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Turbocharger.
5. Models with air conditioning: Remove
auxiliary drive belt.
+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
6. Models with air conditioning: Remove 4 bolts
securing compressor and move to one side.
Page 204 of 1672
ENGINE - TD5
REPAIRS 12-1-65
7.Remove 3 bolts securing centrifuge to engine
oil cooler.
8.Remove centrifuge and discard 'O' ring.
9.Remove 2 bolts, remove drain pipe from
centrifuge and discard gasket. Refit
1.Clean mating faces of centrifuge, oil cooler and
sump.
2.Position new gasket and fit oil drain pipe to
centrifuge, tighten bolts to 10 Nm (7 lbf.ft).
CAUTION: Gasket must be fitted dry.
3.Position new 'O' ring to oil cooler.
4.Position centrifuge to oil cooler housing and
tighten bolts to 25 Nm (18 lbf.ft).
5.Using a new gasket, align the centrifuge oil
drain pipe to sump and tighten bolts to 10 Nm
(7 lbf.ft).
CAUTION: Gasket must be fitted dry.
6. Models with air conditioning: Position A/C
compressor and tighten bolts to 25 Nm (18
lbf.ft).
7.Fit turbocharger.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Turbocharger.
8. Models with air conditioning: Fit auxiliary
drive belt.
+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
9.Fit underbelly panel and secure with fixings.
10.Remove stand(s) and lower vehicle.
Page 262 of 1672
ENGINE - V8
REPAIRS 12-2-19
Gasket - rocker cover - LH
$% 12.29.40
Remove
1.Remove upper inlet manifold gasket.
+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
2. Models with air conditioning: Release 4
clips and remove fan cowl.
3. Models with air conditioning: Release
tension on auxiliary drive belt and remove belt
from air conditioning compressor. Disconnect
compressor multiplug. Remove 4 bolts
securing compressor and position compressor
aside. 4.Release ht leads from rocker cover clips.
5.Remove screw securing dip stick tube.
6.Remove 4 bolts securing rocker cover.
7.Remove rocker cover and collect gasket.
Refit
1.Clean mating faces of rocker cover and
cylinder head.
2.Using a new gasket, fitted dry, position rocker
cover ensuring gasket is correctly located.
3.Fit rocker cover bolts and working in diagonal
sequence, tighten to:
lStage 1 - 3 Nm (2.5 lbf.ft)
lStage 2 - 8 Nm (6 lbf.ft)
4.Ensure that outer rim of gasket is correctly
positioned around periphery of rocker cover.
5.Fit and tighten screw securing dip stick tube.
6.Secure ht leads in rocker cover clips.
7. Models with air conditioning: Clean
compressor dowels and dowel holes. Position
compressor, fit bolts and tighten to 22 Nm (16
lbf.ft). Release auxiliary drive belt tensioner
and fit belt to compressor.
Page 263 of 1672
ENGINE - V8
12-2-20 REPAIRS
8. Models with air conditioning: Position fan
cowl and secure clips.
9.Fit upper inlet manifold.
+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
Gasket - rocker cover - RH
$% 12.29.41
Remove
1.Drain cooling system.
+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
2.Remove upper inlet manifold gasket.
+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Gasket - inlet
manifold - upper - Without Secondary Air
Injection.
3. Models with SAI: Disconnect 2 air manifold
unions from adapters in cylinder head and
remove manifold.
4.Remove 2 bolts securing coolant rails to inlet
manifold.
