1 of 3 3/1/ :50 AM
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1 Fan Clutch Service and Repair, Removal and Replacement 1 of 3 3/1/ :50 AM Coupling unit - Viscous Fan Service Repair No Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. Remove 1. Position vehicle on lift. 2. Disconnect battery earth lead. 3. Remove undertray. 4. Release 3 coolant hoses from clips on fan cowl. Remove screw securing fan cowl to radiator. 5. Disconnect harness multiplug and release cooling fan multiplug from mounting.
2 Fan Clutch Service and Repair, Removal and Replacement 2 of 3 3/1/ :50 AM 6. Use LRT and LRT to loosen viscous coupling lock nut and remove fan assembly from coolant pump. NOTE: Thread is left handed. 7. Remove rivets securing fan cowl. CAUTION: The radiator matrix is a fragile component, to prevent damage do not allow the tan or fan cowl to contact the radiator.
3 Fan Clutch Service and Repair, Removal and Replacement 3 of 3 3/1/ :50 AM 8. Release cowl from mountings and remove cowl and fan assembly. 9. Place viscous coupling and fan to work bench. NOTE: Do not carry out further dismantling if component is removed for access only. 10. Remove 4 bolts and remove coupling from fan. Refit 1. Clean coupling and fan mating faces. 2. Fit viscous coupling to fan and tighten 4 bolts to 10 Nm (7 ft. lbs.). 3. Carefully fit fan and cowl assembly, secure the cowl to mountings. 4. Fit fan assembly to coolant pump. Using LRT and LRT tighten viscous coupling lock nut to 45 Nm (33 ft. lbs.). 5. Fit cooling fan harness and multiplug to fan cowl. 6. Fit screw securing fan cowl to radiator. 7. Secure 3 coolant hoses to clips on fan cowl. 8. Fit undertray. 9. Connect battery earth lead ALLDATA, LLC. All Rights Reserved. (Version )
4 Drive Belt Service and Repair, Procedures 1 of 5 3/1/ :51 AM Ancillary Drive Belt - V8 Service repair No Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. Remove 1. Disconnect battery earth lead. 2. Loosen 2 ancillary drive belt tensioner bolts.
5 Drive Belt Service and Repair, Procedures 2 of 5 3/1/ :51 AM 3. Using a 17 mm (11/16 in') spanner, rotate belt tensioner fully clockwise to release tension on ancillary belt. 4. Hold tensioner in retracted position and tighten tensioner clamping bolt.
6 Drive Belt Service and Repair, Procedures 3 of 5 3/1/ :51 AM 5. Release ancillary drive belt from tensioner pulley. 6. Release and remove ancillary drive belt from remaining pulleys. 7. Slowly rotate fan by hand while positioning ancillary drive belt over fan blades between fan and fan cowl to remove belt. Refit 1. Check drive belt pulleys are damage free. 2. Fit ancillary drive belt over cooling fan assembly. 3. Fit ancillary drive belt to all pulleys except tensioner pulley.
7 Drive Belt Service and Repair, Procedures 4 of 5 3/1/ :51 AM 4. Fit ancillary drive belt to tensioner pulley Ensure ancillary drive belt is aligned to all pulleys. 5. Undo tensioner clamping bolt to release tensioner.
8 Drive Belt Service and Repair, Procedures 5 of 5 3/1/ :51 AM 6. Using a 17 mm (11/16 in') spanner, rotate belt tensioner fully anticlockwise to tension ancillary drive belt. 7. Hold tensioner in the tensioned position and tighten tensioner bolts to 30 Nm (22 lbf.ft). 8. Connect battery earth lead ALLDATA, LLC. All Rights Reserved. (Version )
9 Drive Belt Tensioner Service and Repair, Procedures 1 of 7 3/1/ :51 AM Tensioner - Ancillary Drive Belt - V8 Service repair No Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. Remove 1. Disconnect battery earth lead. 2. Remove fan cowl. 3. Loosen 2 ancillary drive belt tensioner bolts.
10 Drive Belt Tensioner Service and Repair, Procedures 2 of 7 3/1/ :51 AM 4. Using a 17 mm (11/16 in) spanner, rotate belt tensioner fully clockwise to release tension on ancillary drive belt. 5. Hold tensioner in retracted position and tighten tensioner clamping bolt.
11 Drive Belt Tensioner Service and Repair, Procedures 3 of 7 3/1/ :51 AM 6. Release ancillary drive belt from tensioner pulley 7. Remove nut securing tensioner to tensioner adjusting bracket. 8. Remove 2 bolts securing ancillary drive belt tensioner to lower timing gear cover. 9. Remove dust cap from ancillary drive belt tensioner idler pulley and remove Torx bolt securing ancillary drive belt tensioner idler pulley. 10. Remove ancillary drive belt tensioner assembly. 11. Remove bolt and tensioner from pulley mounting. 12. Remove tensioner from tensioner adjusting bracket. Refit 1. Fit tensioner to tensioner adjusting bracket, fit securing nut but do not fully tighten at this stage. 2. Fit tensioner to pulley mounting and tighten securing bolt. 3. Fit pulley and tensioner mounting to timing gear cover and tighten securing bolt. 4. Fit dust cap to tensioner pulley.
12 Drive Belt Tensioner Service and Repair, Procedures 4 of 7 3/1/ :51 AM 5. Fit tensioner to upper timing gear cover fit 2 securing bolts but do not tighten at this stage. 6. Using a 17 mm (11/16 in) spanner rotate belt tensioner fully clockwise.
13 Drive Belt Tensioner Service and Repair, Procedures 5 of 7 3/1/ :51 AM 7. Hold tensioner in retracted position and tighten tensioner clamping bolt. 8. Fit ancillary drive belt to all pulleys except tensioner pulley. 9. Fit ancillary drive belt to tensioner pulley. Ensure ancillary drive belt is aligned to all pulleys.
14 Drive Belt Tensioner Service and Repair, Procedures 6 of 7 3/1/ :51 AM 10. Undo tensioner clamping bolt to release tensioner. 11. Using a 17 mm (11/16 in) spanner rotate belt tensioner fully anticlockwise to tension ancillary drive belt.
15 Drive Belt Tensioner Service and Repair, Procedures 7 of 7 3/1/ :51 AM 12. Hold tensioner in the tensioned position and tighten tensioner bolts to 30 Nm (22 lbf.ft). 13. Tighten tensioner to tensioner adjusting bracket securing nut. 14. Fit fan cowl. 15. Connect battery earth lead ALLDATA, LLC. All Rights Reserved. (Version )
16 Alternator Service and Repair, Procedures 1 of 4 3/1/ :52 AM Alternator - V8 Service repair No Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. Remove 1. Position vehicle on lift. 2. Disconnect battery earth lead. 3. Drain cooling system 4. Remove viscous coupling. 5. Remove ancillary drive belt tensioner. 6. Release clip and disconnect radiator top hose from radiator. 7. Release clips and disconnect radiator top hose from coolant pump and alternator. 8. Position hose aside.
17 Alternator Service and Repair, Procedures 2 of 4 3/1/ :52 AM 9. Disconnect pipe from charcoal canister purge control valve, release valve from bracket and position valve aside. 10. Release battery lead from securing clip on engine timing cover. 11. Disconnect multiplug from alternator.
18 Alternator Service and Repair, Procedures 3 of 4 3/1/ :52 AM 12. Remove nut and disconnect battery cable from alternator. 13. Release alternator harness from securing clip on alternator. 14. Remove 6 bolts securing alternator, remove harness securing clip and remove alternator. Discard alternator 'O' ring. Refit 1. Clean alternator and engine timing gear cover mating face. 2. Lubricate and lit new 'O' ring to alternator. 3. Position alternator to casing fit bolts securing alternator and tighten to 13 Nm (10 lbf.ft). 4. Connect battery lead to alternator and tighten nut securing battery lead to alternator to 13 Nm (10 lbf.ft). 5. Secure battery lead into securing clip on engine timing cover. 6. Connect multiplug to alternator. 7. Secure alternator harness into securing clip on alternator. 8. Fit charcoal canister purge control valve and connect pipe.
19 Alternator Service and Repair, Procedures 4 of 4 3/1/ :52 AM 9. Connect radiator top nose to coolant pump and alternator and secure clips. 10. Connect top hose to radiator and secure with clip. 11. Fit ancillary drive belt tensioner. 12. Fit viscous coupling. 13. Connect battery earth lead. 14. Fill cooling system ALLDATA, LLC. All Rights Reserved. (Version )
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