Page 326 of 1007

FUEL DELIVERY SYSTEM - PETROL
ADJUSTMENTS 19-2-5
Fuel system - pressure test - KV6 - NAS
$% 19.50.13
Remove
1.Remove acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
2.Position absorbent cloth beneath fuel rail.
WARNING: Fuel vapour is highly flammable
and in confined spaces is also explosive
and toxic. Always have a fire extinguisher
containing foam, CO
2, gas or powder close
at hand when handling or draining fuel.
3. Up to 03MY: Remove nut and bolt securing coil
and position coil aside.
4.Connect adaptor LRT-19-006, to pressure
gauge LRT-19-004 .
5.Remove schraeder valve cap.
6.Connect pressure gauge to fuel rail schraeder
valve.
7.Start engine. Pressure at idle = 3.4 bar. If
pressure is below 3.4 bar, suspect the following
in order: fuel hoses, filter, regulator and pump.
Refit
1.Stop engine.
2.Disconnect pressure gauge LRT-19-006 and
adapter LRT-19-004 from fuel rail.
3. Up to 03MY: Fit and tighten nut and bolt
securing coil.
4.Fit acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
Fuel system - pressure test - K1.8
$% 19.50.13
Check
1.Disconnect battery earth lead.
2.Position absorbent cloth beneath fuel pipe to
catch spillage.
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
3.Disconnect fuel pipe from inlet manifold.
4.Connect LRT-19-004A to manifold and fuel
pipe.
Note:: LRT-19-004X can be used as an
alternative.
5.Connect battery earth lead.
6.Start engine. Pressure at idle = 3.6 bar ± 0.2
bar.
7.Stop engine. If pressure is out of tolerance
suspect the following in order: fuel hoses, filter
and pump.
8.Remove plug, reconnect vacuum hose and
secure hose with clip.
9.Disconnect battery earth lead.
10.Disconnect LRT-19-004A from fuel pipe and
inlet manifold.
11.Connect fuel pipe to manifold.
12.Connect battery earth lead.
LRT - 19 -004A
M19 3675
Page 327 of 1007
FUEL DELIVERY SYSTEM - PETROL
19-2-6 ADJUSTMENTS
Fuel tank - drain
$% 19.55.02
Drain
1.Disconnect both battery leads, negative lead
first.
2.Remove fuel pump assembly.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Pump - fuel.
3.Using a fuel recovery appliance, drain the fuel
from the tank into a sealed container. Follow
the manufacturer's instructions for the
connection and safe use of the appliance.
WARNING: Fuel vapour is highly flammable
and in confined spaces is also explosive
and toxic. Always have a fire extinguisher
containing foam, CO
2, gas or powder close
at hand when handling or draining fuel.
Refill
1.Fit fuel pump assembly.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Pump - fuel.
2.Connect battery leads, earth lead last.
Page 328 of 1007
FUEL DELIVERY SYSTEM - PETROL
REPAIRS 19-2-7
REPAIRS
Air cleaner - K1.8
$% 19.10.01
Remove
1.Release air intake duct from air cleaner.
2.Remove clip and disconnect air intake hose
from throttle housing.3.Remove 2 bolts securing air cleaner to battery
tray.
4.Remove air cleaner assembly.
Refit
1.Position air cleaner assembly.
NOTE: Ensure bottom of air cleaner is located
on peg.
2.Fit bolts and tighten to 9 Nm (7 lbf.ft).
3.Connect air intake hose to throttle housing and
secure with clip.
4.Connect air intake duct to air cleaner.
Page 334 of 1007
FUEL DELIVERY SYSTEM - PETROL
REPAIRS 19-2-13
Sensor - heated oxygen (H02S) - pre-
catalyst - LH - KV6 - NAS
$% 19.22.16
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
4.Release and disconnect HO2S multiplug.
5.Release HO2S harness from clip.
6.Remove HO2S.Refit
1.Clean HO2S and mating face.
2.Fit H02S and tighten to 55 Nm (40 lbf.ft).
3.Connect H02S multiplug and fit to bracket.
4.Fit H02S harness to clip.
5.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
6.Fit engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
7.Connect battery earth lead.
M19 3505
M19 3483
Page 337 of 1007

FUEL DELIVERY SYSTEM - PETROL
19-2-16 REPAIRS
Sensor - heated oxygen (H02S) pre-
catalyst - RH - KV6 - NAS
$% 19.22.17
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Release and disconnect HO2S multiplug.
4.Release HO2S harness from clips.
5.Remove HO2S.
Refit
1.Clean HO2S and mating face.
2.Fit H02S and tighten to 55 Nm (40 lbf.ft).
3.Connect H02S multiplug and fit to bracket.
4.Fit harness into clips.
5.Fit engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
6.Connect battery earth lead.
Sensor - mass air flow (MAF) - NAS
$% 19.22.25
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Disconnect multiplug from MAF sensor.
4.Release clip and remove MAF sensor.
Refit
1.Fit MAF sensor and secure with clip.
2.Connect multiplug to MAF sensor.
3.Fit engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
4.Connect battery earth lead.
M19 3483
M19 3482
M19 3480
Page 338 of 1007
FUEL DELIVERY SYSTEM - PETROL
REPAIRS 19-2-17
Relay - fuel pump
$% 19.22.39
Remove
1.Open engine compartment fuse box.
2.Identify and remove fuel pump relay.
Refit
1.Fit fuel pump relay.
2.Close engine compartment fuse box.
Throttle housing - K1.8
$% 19.22.45
Remove
1.Disconnect battery earth lead.
2.Remove clip and disconnect air intake hose
from throttle housing.
3.Release 4 clips and remove lid from air cleaner.
Page 339 of 1007

FUEL DELIVERY SYSTEM - PETROL
19-2-18 REPAIRS
4.Disconnect idle air control valve (IACV) hose
from throttle housing.
5.Disconnect multiplug from throttle position
sensor.
6.Release clip and disconnect breather hose
from throttle housing.
7.Release throttle cable adjusting nut from
abutment bracket.
8.Disconnect throttle cable from throttle cam.
9.Remove 4 bolts securing throttle housing to
inlet manifold.
10.Remove throttle housing.
11.Remove and discard 'O' ring from throttle
housing.Refit
1.Clean mating faces of throttle housing and inlet
manifold.
2.Lubricate new 'O' ring with silicone grease and
fit to throttle housing.
3.Position throttle housing to inlet manifold, align
harness bracket and fit bolts finger tight.
4. Tighten bolts in the sequence shown using the
following procedure.
aTighten to 4 Nm (3 lbf.ft).
bBack off one flat.
cTighten to 9 Nm (7 lbf.ft).
5.Connect throttle cable to throttle cam.
6.Locate throttle cable adjusting nut in abutment
bracket.
7.Connect breather hose to throttle housing and
secure with clip.
8.Connect multiplug to throttle position sensor.
9.Fit IACV hose and align orientation marks.
10.Fit lid to air cleaner and secure clips.
11.Connect air intake hose to throttle housing and
secure with clip.
12.Connect battery earth lead.
13.Retune using Testbook.
Page 340 of 1007
FUEL DELIVERY SYSTEM - PETROL
REPAIRS 19-2-19
Throttle housing - KV6 - Non NAS
$% 19.22.45
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Depress locking collars and release engine
breather/vacuum pipes from throttle and IACV.
4.Release throttle cable from abutment bracket
and disconnect cable from throttle body cam.5. Vehicles with cruise control: Disconnect
vacuum hose from cruise control actuator.
6.Disconnect multiplugs from primary TP sensor
and IACV.
7.Remove 4 Torx screws securing throttle body
to inlet manifold chamber, remove throttle
body.
M19 3198