REPAIRS, Starter motor - diesel.

5. Fit 2 upper bolts securing engine oil cooler pipe 33. Connect hoses to turbocharger boost solenoid and gearbox housing to engine and tighten to 50 Nm (37 lbf.ft) . 34. Clean CKP sensor and mating face.
6. Lower engine onto mountings, and tighten nuts to 85 Nm (63 lbf.ft) .
7. Remove tool LRT-12-138 from engine.
8. Fit and tighten bolt securing engine closing
35. Using new 'O' ring, fit CKP sensor, tighten CKP

panel to gearbox.

9. Raise vehicle on ramp.
10. Fit nuts and bolts securing engine LH and RH
36. Connect multiplug to EGR modulator.

mountings to chassis and tighten to 85 Nm (63

37. Connect engine earth lead to battery earth lead

lbf.ft).

11. Fit remaining bolts securing gearbox housing to
38. Connect engine harness multiplug to ECM and

engine and tighten to 50 Nm (37 lbf.ft).

12. Rotate crankshaft and align drive plate to
39. Connect engine harness multiplugs to fuse

torque converter.

13. Using a magnetic socket, fit and tighten new
40. Position glow plug lead to fusebox and secure

torque converter drive plate bolts to 50 Nm (37 lbf.ft) .

41. Position battery and alternator leads to fusebox
14. Fit front cross member and tighten bolts to 26 Nm (19 lbf.ft).
42. Fit engine compartment fuse box cover.
15. Align gearbox oil cooler pipes.
43. Connect vacuum hose to EGR valve.
16. Fit oil cooler pipe clip and tighten bolts to 9 Nm
44. Connect hose to vacuum pump and secure

(7 lbf.ft).

17. Position gearbox oil cooler pipe clamps and
45. Disconnect fuel hose from connector block and

tighten nuts.

18. Position coolant rail and secure support bracket
46. Connect fuel hoses to fuel cooler and

in engine LH and RH mounting brackets.

19. Fit starter motor.

47. Position expansion tank, connect hose and CHARGING AND STARTING,

REPAIRS, Starter motor - diesel.

48. Connect coolant hoses to fuel cooler and
20. Lower ramp.
21. Position coolant rail to front chassis member, fit
49. Fit turbocharger.

and tighten bolt to 10 Nm (7 lbf.ft).

22. Connect heater hose to coolant rail and secure with clip.
50. Fit radiator.
23. Connect hose to coolant pump and secure with clip.
24. Position PAS pump and tighten bolts to 25 Nm
51. Fill engine with oil.

(18 lbf.ft).

25. Position PAS pump pulley and lightly tighten bolts.
52. Fit underbelly panel.
26. Position ACE pump, fit bolts and tighten to 25 Nm (18 lbf.ft).
27. Position A/C compressor, fit bolts and tighten
53. Fit bonnet.

to 25 Nm (18 lbf.ft).

28. Position ancillary drive belt, rotate tensioner anti-clockwise and locate belt to pulleys.
29. Tighten PAS pump pulley bolts to 10 Nm (7 lbf.ft).
30. Position air intake hose to air cleaner and secure clips.
31. Position engine harness and connect multiplugs to compressor, MAF sensor, turbocharger boost solenoid, AAP & IAT sensor.
32. Position air inlet hose to turbocharger and tighten clip.

and secure clips.

CAUTION: If originally fitted: Fit spacer to CKP sensor.

sensor bolt to 9 Nm (7 lbf.ft) and connect multiplug.

and tighten bolt.

main harness.

box.

with bolt.

and secure with bolts.

vacuum pipe to fuel cooler.

connect to fuel cooler.

connector block on cylinder head.

secure with clip. Secure tank to body mounting.

coolant rail and secure clips.

ENGINE MANAGEMENT SYSTEM - Td5, REPAIRS, Turbocharger.

COOLING SYSTEM - Td5, REPAIRS, Radiator.

MAINTENANCE, PROCEDURES,

Engine oil - diesel engine.

EXTERIOR FITTINGS, REPAIRS,

Panel - underbelly.

EXTERIOR FITTINGS, REPAIRS,

Bonnet.