Page 178 of 873
12ENGINE
20
REPAIR
Exhaust only
13.Fit bolts finger tight.
14.Working from the centre outwards, progressively
tighten bolts to the correct torque.
10Nm
Inlet and exhaust
15.Fit spark plug cover to camshaft cover, tighten
screws.CAMSHAFT DRIVE BELT
Service repair no - 12.65.17
Remove
NOTE: If the timing belt is to be removed
from the camshaft gears only, it is not
necessary to remove the drive belt,
crankshaft pulley or timing belt lower cover.
1.Remove drive belt.
2.Remove 5 bolts securing timing belt top cover.
3.Remove top cover.
4.Remove 5 bolts securing timing belt centre
cover.
5.Remove timing belt centre cover.
6.Rotate crankshaft to align timing marks on
camshaft gears - 90°BTDC.
Page 179 of 873
Mpi
21
REPAIR
CAUTION: Never use the camshaft gears,
gear retaining bolts or timing belt to rotate
crankshaft.
7.Fit tool LRT-12-058 to lock flywheel.
8.Position tool LRT-12-060 to lock camshaft gears.
9.Loosen camshaft belt tensioner pulley bolt.
10.Move tensioner to release timing belt tension.
11.Retighten tensioner pulley bolt.
12.Remove 4 bolts securing crankshaft pulley to
crankshaft timing gear.13.Fit tool LRT-12-059 to crankshaft pulley, fit 2
pulley bolts to retain tool.
14.Restrain crankshaft pulley using tool LRT-12-059
and remove crankshaft pulley bolt.
15.Remove bolts securing tool LRT-12-059, remove
crankshaft pulley.
16.Remove timing belt lower cover.
17.If timing belt is to be refitted, mark direction of
rotation of belt.
18.Remove timing belt.
Page 180 of 873

12ENGINE
22
REPAIR
CAUTION: Ease timing belt off gears using
fingers only. Metal levers may damage the
belt and gears. Do not rotate engine with
timing belt removed and cylinder head fitted.
Timing belts must be stored and handled with
care. Always store a timing belt on its edge with a
bend radius greater than 50 mm. Do not use a
timing belt which has been twisted or bent double
as this can fracture reinforcing fibres. Do not use
an oil contaminated timing belt. Although the belt
has a service life of 96,000 miles, 160,000 km, an
existing belt should only be refitted if it has
completed less than 48,000 miles, 80,000 km.
Refit
NOTE: For torque values.See
Specifications, torque, Torque values
1.Clean timing belt gears and pulleys.
2.Clean crankshaft pulley.
CAUTION: If original belt is to be refitted,
ensure direction of rotation mark is facing
correct way.
3.Fit timing belt to gears, starting at the crankshaft
gear and working in an anti-clockwise direction.
CAUTION: Ensure the belt run between the
crankshaft and exhaust camshaft gear is
kept taut during the fitting procedure.
4.Fit timing belt lower cover, tighten 3 bolts to the
correct torque.
5.Fit crankshaft pulley to crankshaft timing gear.
6.Fit tool LRT-12-059 to crankshaft pulley, fit 2
bolts to retain tool.
7.Fit crankshaft pulley centre bolt, and using tool
LRT-12-059 to restrain pulley, tighten bolt to the
correct torque.
8.Remove tool LRT-12-059
9.Fit bolts securing crankshaft pulley to timing
gear, tighten bolts to the correct torque.
10.Remove tool LRT-12-060.Tension belt
1.Loosen timing belt tensioner pulley bolt.
2.Apply
40Nmanti-clockwise torque to inlet cam
pulley bolt and release.
3.Tighten tensioner pulley bolt to the correct
torque.
4.Remove tool LRT-12-058 from flywheel.
5.Fit timing belt centre cover, tighten 5 bolts to the
correct torque.
6.Fit timing belt upper cover, tighten 5 bolts to the
correct torque.
7.Fit drive belt.
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23
REPAIR CHECK CAMSHAFT DRIVE BELT
Service repair no - 12.65.17
CAUTION: This check must be carried out
at the service intervals specified and
whenever carrying out any repair which
requires the timing belt to be disturbed. Pay
particular attention for signs of belt splitting at
base of teeth.
1.Remove 5 bolts securing timing belt upper cover
2.Remove upper cover.
3.Using a socket and extension bar on the
crankshaft pulley bolt, rotate engine to allow the
timing belt to be inspected.
CAUTION: Do not use camshaft gears or
retaining bolts to rotate engine.
4.Check timing belt condition, renew any belt that
shows signs of oil contamination, cracking,
fraying or splitting at base of teeth.
CAUTION: Cause of oil contamination, if
present, must be rectified.
5.Clean timing belt upper cover.
6.Position upper cover.
7.Fit upper cover securing bolts.
Page 197 of 873

EMISSION CONTROL
1
REPAIR POSITIVE CRANKCASE VENTILATION AIR
INTAKE FILTER
Service repair no - 17.10.02
The PCV air intake filter is located at the rear of the
left hand rocker cover, beneath the throttle linkage
bracket.
Remove
1.Pry the filter outer cover upwards to release it
from its mounting.
2.Remove the sponge filter from the cover and
discard the sponge.
Refit
3.Insert a new filter into the filter cover.
4.Press the filter onto its mounting until it clips
firmly into position.POSITIVE CRANKCASE VENTILATION BREATHER
FILTER
Service repair no - 17.10.03
Remove
1.Release the hose clamp and pull the hose off the
canister.
2.Unscrew the canister and remove it from the
rocker cover.
3.Remove the large rubber 'O' ring and inspect for
deterioration.
4.Visually inspect the condition of the wire screen
within the canister, if in poor condition, replace
the whole assembly, if the filter unit is in an
acceptable condition, clean as follows.
5.Immerse the canister in a small amount of
solvent (mineral spirits) and allow time for the
solvent to dissolve or loosen any debris.
6.Remove the canister from the solvent bath and
allow to dry in still air.
WARNING: Do not use a compressed air
line to dry, clean or remove any remaining
particles of debris within the canister as
this could cause fire or personal injury.
Refit
7.If the original canister is being refitted, fit a new
'O' ring.
8.Screw the canister into the rocker cover securely
- hand tight only.
9.Refit the hose and tighten the hose clamp
securely.
Page 198 of 873

17EMISSION CONTROL
2
REPAIR HEATED OXYGEN SENSOR (HO2S)
Service repair no - 19.26.16
CAUTION: The removal of the sensors
from the exhaust system must only be
carried out when the engine is cold.
Remove
1.Disconnect battery negative lead.
2.Disconnect the electrical plugs from the sensors.
3.Unscrew and remove the sensors from the two
exhaust downpipes.
Refit
4.Coat the threads of the sensors with anti-seize
compound.
CAUTION: To ensure that the efficiency of
the sensor is not impaired, DO NOT allow
anti-seize compound to come into contact
with the sensor nose.
5.Screw in the sensor and tighten to the correct
torque using special tool LST134.
6.Connect the electrical plugs and battery lead.PURGE CONTROL VALVE
Service repair no - 17.15.39
Remove
1.Disconnect battery negative lead.
2.Disconnect multiplug from purge control valve.
3.Release clip and disconnect hose from valve.
4.Release valve from charcoal canister.
5.Remove valve.
6.Discard 'O' ring.
Refit
7.Clean valve and valve location.
8.Fit new 'O' ring to purge valve.
9.Position and secure valve to charcoal canister.
10.Connect hose to purge valve and secure with
clip.
11.Connect multiplug to valve.
12.Reconnect battery negative lead.
Page 201 of 873
EMISSION CONTROL
5
REPAIR Rear sensors
9.Release sensor cable from clips.
10.Release multiplug from bracket and disconnect.
11.Unscrew and remove sensor from exhaust pipe
using special tool LRT-12-047 (LST134).Refit
12.Ensure mating faces are clean.
NOTE: New HO2S is supplied pre-treated
with anti-seize compound.
13.If refitting existing HO2S, coat threads with
anti-seize compound.
CAUTION: Do not allow anti-seize
compound to come into contact with HO2S
nose or enter exhaust system.
14.Position HO2S with new sealing washer on
exhaust pipe. Tighten to
20 Nmusing special
tool LRT-12-047 (not RH front sensor).
15.Reconnect multiplug to engine harness and
secure to bracket.
16. RH front sensor only:
Place coil bracket in position and fit nuts. Tighten
to
8 Nm.
CAUTION: Ensure sensor leads are
secured using clips provided. Failure to
correctly secure leads could result in
damage to HO2S.
17.Remove stands. Lower vehicle.
Page 202 of 873
17EMISSION CONTROL
6
REPAIR CATALYTIC CONVERTER/FRONT PIPE - 4.0 V8
Service repair no - 17.50.09
WARNING: The removal of the exhaust
system must only be carried out when the
engine is cold.
Remove
1.Disconnect battery negative lead.
2.Raise vehicle on ramp.
3.Remove oxygen sensors
See Heated Oxygen
Sensor (HO2S) - 4.0 V8
4.Remove 4 nuts/bolts securing front anti-roll bar
brackets.
5.Remove 6 nuts securing front pipe flanges to
manifolds.
6.Remove 2 nuts securing front pipe to
intermediate pipe.
7.With assistance, release front pipe from manifold
flanges.8.With assistance, release front pipe from
intermediate pipe.
9.With assistance, lower anti-roll bar.
10.With assistance, remove exhaust front pipe.
11.Remove flange gaskets and discard.
Refit
12.Reverse removal procedure.