Page 342 of 1007
FUEL DELIVERY SYSTEM - PETROL
REPAIRS 19-2-21
Refit
1.Clean mating faces of IACV and throttle body.
2.Fit new gasket, position IACV to throttle body,
fit and tighten Allen screws to 6 Nm (4.5 lbf.ft).
3.Clean TP sensor and throttle body mating face.
4.Fit TP sensor to throttle spindle. Ensure that
during fitting the machined flat on the throttle
spindle is aligned with the mating portion of the
TP sensor
CAUTION: The throttle position sensor can
be easily damaged during fitting. When
pressing the sensor onto the throttle
spindle, use fingers only, and only apply
pressure to the area shown shaded in the
illustration.
5.Rotate TP sensor in an anti-clockwise direction
to align fixing holes.
CAUTION: Do not rotate throttle position
sensor in a clockwise direction and ensure
that it is not rotated beyond its internal
stops.
6.Fit TP sensor specification plate.
7.Fit new Torx screws and wave washers, tighten
Torx screws to 1.5 Nm _1.0 lbf.ft).
8. Vehicles with cruise control: Position
actuator support bracket to throttle body. Fit
Torx screws and tighten to 9 Nm (7 lbf.ft).
Connect actuator arm to throttle linkage.
9.Clean throttle body and mating face on inlet
manifold chamber.
10.Fit new seal to inlet manifold chamber.
11.Position throttle body to inlet manifold chamber,
fit and tighten Torx screws to 7 Nm ( 5 lbf.ft).
12.Connect multiplugs to TP sensor and IACV.
13. Vehicles with cruise control: Connect cruise
control actuator vacuum hose.
14.Connect primary throttle cable to throttle cam
and abutment bracket.
15.Connect engine breather/vacuum pipes to
throttle body and IACV.16.Adjust throttle cable.
+ FUEL DELIVERY SYSTEM -
PETROL, ADJUSTMENTS, Throttle cable -
check and adjust - KV6.
17.Connect battery earth lead.
18.Fit engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
19.Retune using TestBook
M18 0695
Page 343 of 1007
FUEL DELIVERY SYSTEM - PETROL
19-2-22 REPAIRS
Throttle housing - KV6 - NAS
$% 19.22.45
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
Pre 03MY illustrated.
3.Disconnect multiplug from MAF sensor.
4.Disconnect multiplug from IAT sensor.
5.Release clip and disconnect vacuum enhancer
from intake hose.
Pre 03MY illustrated.
6.Disconnect engine breather pipe from intake
hose.
7.Disconnect injector air supply pipe from intake
hose.Pre 03MY illustrated.
8.Disconnect multiplug from throttle body.
9.Release clip and remove intake hose and MAF
sensor assembly.
10.Remove 4 Torx screws securing throttle body.
11.Remove throttle body and discard gasket.
Refit
1.Clean throttle body and mating face.
2.Using a new seal, fit throttle body and tighten
Torx screws to 7 Nm (5.2 lbf.ft).
3.Connect multiplug to throttle body.
4.Fit intake hose assembly and secure with clip.
5.Connect engine breather pipe.
6.Connect injector air supply pipe.
7.Connect vacuum enhancer and secure with
clip.
8.Connect IAT sensor multiplug.
9.Connect multiplug to MAF sensor.
10.Fit engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
11.Connect battery earth lead.
Page 344 of 1007
FUEL DELIVERY SYSTEM - PETROL
REPAIRS 19-2-23
Variable induction system (VIS) balance
motor - KV6
$% 19.22.64
This procedure also covers the VIS power valve
motor, 19.22.65.
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
aBalance valve VIS motor.
bPower valve VIS motor.
3.Disconnect multiplug from VIS motor to be
removed.
4.Remove 4 screws securing VIS motor to inlet
manifold chamber.
5.Carefully remove VIS motor from inlet manifold
chamber.Refit
1.Clean VIS motor and manifold chamber mating
faces.
2.Ensure that the seal which is already fitted on
the new VIS motor is correctly positioned.
3.Fit VIS motor, carefully locating drive pin into
groove and seal correctly positioned on the
manifold chamber.
4.Fit and tighten screws securing VIS motor to
inlet manifold chamber to 1.7 Nm (1.25 lbf.ft).
5.Connect multiplug to VIS motor.
6.Fit engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
7.Connect battery earth lead.
Page 346 of 1007
FUEL DELIVERY SYSTEM - PETROL
REPAIRS 19-2-25
Sensor - heated oxygen (H02S) - post
catalyst - LH - KV6 - NAS
$% 19.22.71
Remove
1.Disconnect battery earth lead.
2.Raise front of vehicle and support on stands.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
3.Release HO2S harness from clips.
4.Release and disconnect HO2S multiplug.
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.Remove stands and lower vehicle.
6.Connect battery earth lead.
M19 3481
Page 348 of 1007
FUEL DELIVERY SYSTEM - PETROL
REPAIRS 19-2-27
Sensor - heated oxygen (H02S) - post
catalyst - RH - KV6 - NAS
$% 19.22.72
Remove
1.Disconnect battery earth lead.
2.Raise vehicle on 4 post ramp.
3.Release HO2S harness from clips.
4.Release and disconnect HO2S multiplug.
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.Lower ramp.
6.Connect battery earth lead.
M19 3505
M19 3483
Page 349 of 1007
FUEL DELIVERY SYSTEM - PETROL
19-2-28 REPAIRS
Filter - main
$% 19.25.02
Remove
1.Disconnect battery earth lead.
2.Remove sender unit.
+ INSTRUMENTS, REPAIRS, Sender
unit - fuel tank gauge.
3.Disconnect 2 Lucars from top of pump unit
assembly.
4.Release 3 slots in top of pump unit assembly
from lugs in base.
5.Carefully manoeuvre top of pump unit
assembly away from base, ensuring that fuel
feed hose does not become strained.
6.Collect compression spring from fuel filter.
7.Carefully release 3 sprag clips securing fuel
filter.8.Release fuel filter from inlet and outlet
connections.
9.Remove fuel filter.
10.Collect 'O' rings.
Refit
1.Lubricate NEW 'O' rings with silicone grease
and fit to ports.
2.Carefully fit fuel filter to ports and push fully
home, ensuring that sprag clips engage fully.
WARNING: Ensure earthing spring fitted to
fuel pressure regulator is correctly located.
3.Position spring to fuel filter recess and engage
in top location.
WARNING: Ensure that filter earthing tag is
correctly located to contact the base of fuel
filter.
4.Engage pump top to base, ensuring that slots
engage correctly with lugs.
WARNING: During refit, ensure that all
electrical connections are made correctly.
Earth tag on fuel pump negative terminal
must not become distorted.
5.Fit sender unit.
+ INSTRUMENTS, REPAIRS, Sender
unit - fuel tank gauge.
6.Connect battery earth lead.
Page 350 of 1007
FUEL DELIVERY SYSTEM - PETROL
REPAIRS 19-2-29
Pump - fuel
$% 19.45.08
WARNING: If fuel tank is full, using a fuel
recovery appliance, drain excess fuel from fuel
filler neck until a level below height of fuel pump
is obtained.
Remove
1.Disconnect battery earth lead.
2.Open RH rear and tail doors.
3.Fold RH rear seat forward.
4.Remove 2 fasteners securing front and rear
carpets.
5.Pull back loadspace carpet from fuel pump
access panel.
6.Remove 6 screws securing access panel.
WARNING: Depressurise the system before
disconnecting any components. Fuel
pressure will be present in the system even
if the ignition has been switched off for
some time.
7.Remove access panel.
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
8.Disconnect multiplug and fuel hose from fuel
pump housing.
CAUTION: Always fit plugs to open
connections to prevent contamination.9.Use LRT-19-009 to remove locking ring from
fuel pump housing.
10.Remove fuel pump housing and discard sealing
ring.
Refit
1.Clean fuel pump housing and mating face on
fuel tank.
2.Fit new seal to fuel pump housing.
3.Fit fuel pump housing to fuel tank, fit and tighten
locking ring to 35 Nm (26 lbf.ft) using LRT-19-
009.
4.Connect multiplug and fuel hose to fuel pump
housing.
5.Fit access panel and secure with screws.
6.Position carpet and secure with fasteners.
7.Reposition rear seat.
8.Close rear and tail doors.
9.Connect battery earth lead.
Page 351 of 1007
FUEL DELIVERY SYSTEM - PETROL
19-2-30 REPAIRS
Tank - Non NAS
$% 19.55.01
Remove
1.Position vehicle on ramp.
2.Disconnect battery earth lead.
3.Remove fuel pump assembly.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Pump - fuel.
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
4.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: The fuel tank must be drained
before it is removed from the vehicle.
5.Remove intermediate exhaust pipe.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES 1.8, REPAIRS, Exhaust pipe -
intermediate.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Intermediate
pipe - Non NAS.
6.Remove propeller shaft.
+ DRIVESHAFTS, REPAIRS, Propeller
shaft assembly.
7.Remove RH rear wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
8.Release clip from breather hose and
disconnect breather hose from filler neck.
9.Release clip and disconnect vent hose from
fuel tank on vapour separator.10.Remove tamper proof cover from filler hose clip
and loosen clip.
11.Support weight of rear subframe and remove 4
bolts securing subframe to body.
12.Lower subframe.
CAUTION: Do not allow sub frame to hang
on rear brake hoses.
