Page 290 of 1007

ENGINE - K SERIES KV6
OVERHAUL 12-3-113
11.Position an Allen key in tensioner backplate
and hold tensioner pulley against timing belt.
12.With assistance, position timing belt tensioner,
fit new Patchlok bolts and tighten to 25 Nm (18
lbf.ft).
CAUTION: Ensure tensioner plunger is
contacting underside of tensioner
backplate.
13.Remove tools LRT-12-175 from rear timing belt
gears.
14.Fit tools LRT-12-196 to both front inlet
camshaft gears and into the end of each
exhaust camshaft.
CAUTION: Special tools must be fitted when
tightening or loosening gear retaining bolts,
otherwise damage to camshafts may occur.
15.Tighten front inlet camshaft gear bolts to:
lStage 1 - 27 Nm (20 lbf.ft)
lStage 2 - Further 90°
16.Remove tools LRT-12-196 from both inlet
camshaft gears and exhaust camshafts.17.Remove wedge from between drive belt and oil
pump belt guard.
18.Remove 1.5 mm diameter pin from tensioner.
19.Clean exhaust camshaft front cap seal
locations and fit new cap seals.
CAUTION: The sealing edge of the cap seal
and mating face must be clean and dry.
20.Position engine front mounting plate and
manoeuvre plate into position; fit bolts but do
not tighten at this stage.
21.Fit bolts securing IRD support bracket to front
mounting plate; do not tighten bolts at this
stage.
22.Tighten bolts in the sequence shown:
lM10 bolt - No.1 - 25 Nm (18 lbf.ft)
lM10 bolt - No. 5 - 45 Nm (33 lbf.ft)
lBolts Nos. 2, 3, 4, 6 and 7 - 85 Nm (63 lbf.ft)
23.Position engine lifting bracket, fit bolts securing
lifting bracket and front mounting plate to
cylinder block and RH cylinder head and
tighten to:
lM8 bolt - 25 Nm (18 lbf.ft)
lM10 bolts - 45 Nm (33 lbf.ft)
24.Fit rubber blanking plug around tensioner.
25.Clean end of dipstick tube.
26.Position dipstick tube to sump and cylinder
block, fit bolt and tighten to 9 Nm (7 lbf.ft).
27.Clean lower timing belt cover.
28.Position lower timing belt cover, fit and tighten
bolts to 9 Nm (7 lbf.ft).
29.Remove timing pin LRT-12-232.
30.Clean crankshaft pulley.
31.Fit crankshaft pulley to crankshaft gear and
ensure that the indent on pulley locates over
the lug on crankshaft gear.
32.Fit crankshaft pulley bolt and washer, position
LRT-12-161 with LRT-12-199 into crankshaft
pulley. Tighten pulley bolt to 160 Nm (118
lbf.ft).
33.Remove tools LRT-12-161 and LRT-12-199.
34.Clean ancillary drive belt tensioner.
Page 306 of 1007

ENGINE MANAGEMENT SYSTEM - SIEMENS
REPAIRS 18-3-1
ENGIN E MANAGEMENT SY STEM - SIEMENS REPAIRS
Spark plugs - up to 03MY
$% 18.20.02
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3. RH bank only: Release locking clips and
disconnect multiplugs from plug top coils.
4. RH bank only: Remove 6 bolts securing plug
top coils to RH camshaft cover and remove
coils.
5. LH bank only: Noting their fitted positions,
disconnect ht leads.
6.Using a 16 mm plug socket, remove spark
plugs from both cylinder heads.Refit
1.Set gap of each new spark plug to 1.00 mm.
2.Fit spark plugs and tighten to 25 Nm (18 lbf.ft).
3. LH bank only: Connect ht leads.
4. RH bank only: Fit plug top coils to spark plugs.
5. RH bank only: Fit bolts securing plug top coils
to RH camshaft cover and tighten to 9 Nm (6.5
lbf.ft).
6. RH bank only: Connect multiplugs to plug top
coils and secure with locking clips.
7.Fit engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
8.Connect battery earth lead.
Page 307 of 1007
ENGINE MANAGEMENT SYSTEM - SIEMENS
18-3-2 REPAIRS
Spark plugs - from 03MY
$% 18.20.02
Remove
1.Disconnect battery earth lead.
2.Remove the engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Release locking clips and disconnect
multiplugs from plug top coils.
4.Remove 6 bolts securing plug top coils to
cylinder heads.
5.Pull to release and remove 6 plug top coils from
cylinder heads.
6.Using a 16 mm plug socket, remove spark
plugs from cylinder heads.Refit
1.Check and if necessary set spark plug gap.
+ GENERAL DATA, Engine - KV6
Petrol.
2.Fit spark plugs and tighten to 25 Nm (18 lbf.ft).
3.Apply a rubber lubricant to plug top coil lower
seals and fit coils fully into cylinder heads.
4.Fit bolts securing plug top coils and tighten to
10 Nm (7 lbf.ft).
5.Connect and secure multiplugs to plug top
coils.
6.Fit the engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
7.Connect battery earth lead.
Page 308 of 1007

ENGINE MANAGEMENT SYSTEM - SIEMENS
REPAIRS 18-3-3
Coil - each - LH bank - up to 03MY
$% 18.20.46
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Release ht lead from plug top coil.
4.Release locking clip and disconnect multiplug
from plug top coil.
5.Remove nut, release earth lead, remove bolt
securing plug top coil to LH inlet manifold and
remove coil.
Refit
1.Fit plug top coil to LH inlet manifold, position
earth lead, fit and tighten nut and bolt to 9 Nm
(6.5 lbf.ft).
2.Connect multiplug to plug top coil and secure
with locking clip.
3.Connect ht lead to plug top coil.
4.Fit engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
5.Connect battery earth lead.
Coil - each - LH bank - from 03MY
$% 18.20.46
Remove
1.Disconnect battery earth lead.
2.Remove the engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Withdraw multiplug lock, release and
disconnect plug top coil multiplug.
4.Remove bolt securing plug top coil to camshaft
rocker cover.
5.Remove plug top coil from camshaft rocker
cover.
Refit
1.Apply a rubber lubricant to plug top coil, lower
seal.
2.Fit plug top coil to camshaft rocker cover, fit bolt
and tighten to 5 Nm (3.7 lbf.ft).
3.Fit and secure plug top coil multiplug.
4.Fit the engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
5.Connect the battery earth lead.
Page 309 of 1007

ENGINE MANAGEMENT SYSTEM - SIEMENS
18-3-4 REPAIRS
Coil - each - RH bank - up to 03MY
$% 18.20.47
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Release locking clip and disconnect multiplug
from plug top coil.
4.Remove 2 bolts securing plug top coil to RH
camshaft cover.
5.Release and remove plug top coil from spark
plug.
Refit
1.Position and fit plug top coil to spark plug.
2.Fit bolts securing plug top coil to RH camshaft
cover and tighten to 9 Nm (6.5 lbf.ft).
3.Connect multiplug to plug top coil and secure
with locking clip.
4.Fit engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
5.Connect battery earth lead.
Coil - each - RH bank - from 03MY
$% 18.20.47
Remove
1.Disconnect battery earth lead.
2.Remove the engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Withdraw multiplug lock, release and
disconnect plug top coil multiplug.
4.Remove bolt securing plug top coil to camshaft
rocker cover.
5.Remove plug top coil from camshaft rocker
cover.
Refit
1.Apply a rubber lubricant to plug top coil, lower
seal.
2.Fit plug top coil to camshaft rocker cover, fit bolt
and tighten to 5 Nm (3.7 lbf.ft).
3.Fit and secure plug top coil multiplug.
4.Fit the engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
5.Connect the battery earth lead.
Page 317 of 1007
ENGINE MANAGEMENT SYSTEM - SIEMENS
18-3-12 REPAIRS
Sensor - camshaft position (CMP)
$% 18.30.24
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Release CMP multiplug from bracket and
disconnect multiplug.
4.Remove bolt securing CMP sensor multiplug
bracket and release CMP sensor lead from
behind bracket.
5.Remove bolt securing CMP sensor to camshaft
cover.
6.Remove CMP sensor and discard seal.Refit
1.Clean CMP sensor and mating face.
2.Lubricate new seal with clean engine oil and fit
to CMP sensor.
3.Position CMP sensor, fit and tighten bolt to 8
Nm (6 lbf.ft).
4.Feed CMP sensor lead behind multiplug
bracket, align bracket, fit bolt and tighten to 8
Nm (6 lbf.ft).
5.Connect CMP sensor multiplug and secure to
bracket.
6.Fit engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
7.Connect battery earth lead.
Page 324 of 1007
FUEL DELIVERY SYSTEM - PETROL
ADJUSTMENTS 19-2-3
Fuel system - depressurise - KV6 - NAS
$% 19.50.02
Check
1.Remove acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
2. Up to 03MY: Remove nut and bolt securing coil
and position coil aside.
3.Remove schraeder valve cap.
4.Position absorbent cloth around fuel feed pipe
connection to collect spillage.
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.5.Connect adapter LRT-19-006 to schraeder
valve.
6.Position opposite end of adapter LRT-19-006
into container, turn tap to release pressure.
7.Remove adapter LRT-19-006 from schraeder
valve.
8.Fit cap to schraeder valve.
9. Up to 03MY: Fit and tighten nut and bolt
securing coil.
10.Fit acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
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