Page 145 of 1007

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
09-2
Fluids
Fuel
Always use the following recommended fuels:
Petrol engines
Use unleaded petrol with a minimum octane rating of
95 RON to ENN 228 specification.
In an emergency (and only if the correct fuel is
unavailable), lower octane rated fuel can be used for
very limited periods of moderate, low speed
motoring, provided engine 'knocking' does not occur.
Fuels of 90 RON is used in certain markets; 90 RON
fuel can be used regularly ONLY if the engine has
been tuned specifically to suit low octane fuel.
Certain markets use fuel containing a 23% Ethanol
additive.
K1.8 and KV6 engines are also available for use with
a low octane leaded fuel specification in some
markets.
Diesel engines
Use a good quality diesel fuel or automotive gas oil
(AGO) conforming to EN 590 specification.
It is important that the sulphur content of diesel fuel
does not exceed 0.3%.
Ensure the fuel filter element is changed at the
recommended intervals.
+ MAINTENANCE, MAINTENANCE, Fuel
Filter - Diesel.
Brake Fluid
Use only DOT 4 brake fluid. DO NOT use brake fluid
of a different specification.
PAS fluid
Use Texaco 9226 fluid.Anti-freeze solutions
The overall anti-freeze concentration should not fall,
by volume, below 50% to ensure that the anti-
corrosion properties of the coolant are maintained.
Anti-freeze concentrations greater than 60% are not
recommended as cooling efficiency will be impaired.
Use Havoline Extended Life Coolant (XLC), or any
ethylene glycol based anti-freeze (containing no
methanol) with only Organic Acid Technology (OAT)
corrosion inhibitors, to protect the cooling system.
CAUTION: No other anti-freeze should be used
with Havoline Extended Life Coolant.
The cooling system should be drained, flushed and
refilled with the correct amount of anti-freeze
solution at the intervals given on the Service
Maintenance Check Sheet.
After filling with anti-freeze solution, attach a warning
label to a prominent position on the vehicle stating
the type of anti-freeze contained in the cooling
system to ensure that the correct type is used for
topping-up.
The following recommended quantities of anti-freeze
will provide frost protection to -36 °C (-33 °F):
Engine – Td4
Engine – K1.8
Engine – KV6
Concentration 50%
Amount of anti-freeze 3.75 litres
(6.625 imp. pts)
Concentration 50%
Amount of anti-freeze 2.9 litres
(5.125 imp. pts)
Concentration 50%
Amount of anti-freeze 3.9 litres
(6.875 imp. pts, )
Page 157 of 1007

MAINTENANCE
10-10 MAINTENANCE
Fuel Filter - Petrol
Replace
1.Renew fuel filter.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Filter - main.
Fuel Filter - Diesel
Replace
1.Replace fuel filter element.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Filter - main - up to 03MY.
Fuel Pump and Filter assembly - Diesel -
03 Model Year onwards
Remove
1.Remove fuel pump and filter assembly.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Pump and filter assembly - from
03MY.
2.Remove all traces of dirt from fuel pump and
filter assembly.
WARNING: Suitable eye protection must be
worn.
Refit
1.Fit fuel pump and filter assembly.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Pump and filter assembly - from
03MY.
Fuel Sedimenter - Diesel - 03 Model Year
onwards
Drain
1.Position suitable container beneath
sedimenter.
2.Loosen but do not remove sedimenter drain
plug.
WARNING: Suitable hand protection must
be worn.
3.Allow sedimenter to drain until fuel, free from
water, flows from drain hole.
4.Tighten sedimenter drain plug.
Page 160 of 1007
MAINTENANCE
MAINTENANCE 10-13
Vent filter - turbocharger boost control
solenoid valve - Td4
Replace
1.Replace turbocharger solenoid valve vent filter.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Vent filter - turbocharger boost
control solenoid valve - Td4.
Spark Plugs – K1.8
Check & Renew
1.Check spark plugs condition and gap. Renew if
necessary.
+ ENGINE MANAGEMENT SYSTEM -
MEMS, REPAIRS, Spark plugs.
Spark Plugs – KV6
Check & Renew
1.Check spark plugs condition and gap. Renew if
necessary.
+ ENGINE MANAGEMENT SYSTEM -
SIEMENS, REPAIRS, Spark plugs - up to
03MY.
Air Cleaner – Petrol Models
Replace
1.Replace air cleaner element.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Element - air cleaner -
KV6.
Clean
1.Clean the drain hole in filter casing.
Page 163 of 1007
MAINTENANCE
10-16 MAINTENANCE
Camshaft Timing Belt – KV6
Check
1.Check camshaft drive belt and renew if
necessary.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
Brake/Clutch Reservoir
Check/Top-up
RHD shown, LHD similar
1.Check fluid level in brake/clutch fluid reservoir.
2.Clean area around filter cap, remove cap.
3.Top-up if necessary to correct level on reservoir
using recommended fluid.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Fluids.
4.Fit filler cap.
Page 169 of 1007

MAINTENANCE
10-22 MAINTENANCE
Engine Oil and Filter – Td4
Drain
1.Raise vehicle on ramp.
2.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Place a suitable container under engine sump
drain plug, remove drain plug and discard
sealing washer. Allow oil to drain.
WARNING: Observe due care when draining
engine oil as the oil can be very hot.
WARNING: Avoid excessive skin contact
with used engine oil. Used engine oil
contains potentially harmful contaminants
which may cause skin cancer or other
serious skin disorders.
4.Lower vehicle
5.Remove oil filter cap and discard 3 seals.
CAUTION: Care must be taken to ensure
that oil or fluid does not enter or
contaminate the alternator.Refill
1.Replace engine oil filter.
+ ENGINE - Td4, REPAIRS, Filter -
engine oil.
2.Fit new seals and lubricate with clean engine
oil.
3.Fit oil filter cap and tighten to 25 Nm (18 lbf.ft).
4.Raise vehicle.
5.Clean sump drain plug, fit new sealing washer
and tighten sump drain plug to 28 Nm (21 lbf.ft).
6.Fit oil filler cap.
7.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
8.Lower vehicle.
9.Remove engine oil filler cap and fill engine with
oil to correct level.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
10.Start engine. Run at idle until oil pressure
warning light extinguishes.
11.Stop engine. Recheck engine oil level.
12.Check for signs of leakage.
Page 170 of 1007

MAINTENANCE
MAINTENANCE 10-23
Engine Oil and Filter – K1.8
Drain
1.Raise vehicle on ramp.
2.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Place a suitable container under engine sump
drain plug, remove plug and discard sealing
washer. Allow oil to drain.
WARNING: Observe due care when draining
engine oil as the oil can be very hot.
WARNING: Avoid excessive skin contact
with used engine oil. Used engine oil
contains potentially harmful contaminants
which may cause skin cancer or other
serious skin disorders.
4.Remove and discard engine oil filter.Refill
1.Lubricate sealing ring of new filter with clean
engine oil.
2.Fit new filter and tighten by hand until it seats,
then tighten a further half a turn.
3.Clean sump drain plug and fit new sealing
washer.
4.Fit sump drain plug and tighten to 25 Nm (18
lbf.ft).
5.Remove engine oil filler cap and fill engine with
oil to correct level.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
6.Fit oil filler cap.
7.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
8.Lower vehicle.
9.Start engine. Run at idle until oil pressure
warning light extinguishes.
10.Stop engine. Recheck engine oil level.
11.Check for signs of leakage.
Page 171 of 1007

MAINTENANCE
10-24 MAINTENANCE
Engine Oil and Filter – KV6
Drain
1.Raise vehicle on ramp.
2.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Place a suitable container under engine sump
drain plug, remove plug and discard sealing
washer. Allow oil to drain.
WARNING: Observe due care when draining
engine oil as the oil can be very hot.
WARNING: Avoid excessive skin contact
with used engine oil. Used engine oil
contains potentially harmful contaminants
which may cause skin cancer or other
serious skin disorders.
4.Remove and discard engine oil filter.
+ ENGINE - K SERIES KV6, REPAIRS,
Filter - engine oil.Refill
1.Fill canister of replacement oil filter with clean
engine oil.
2.Lubricate sealing ring of new filter with clean
engine oil.
3.Fit new filter and tighten by hand until it seats,
then tighten a further half turn.
4.Clean sump drain plug and fit new sealing
washer.
5.Fit sump drain plug and tighten to 25 Nm (18
lbf.ft).
6.Remove engine oil filler cap and fill engine with
oil to correct level.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
7.Fit oil filler cap.
8.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
9.Lower vehicle.
10.Start engine. Run at 2500 rev/min until oil
pressure warning light extinguishes.
11.Stop engine. Recheck engine oil level.
12.Check for signs of leakage.
Page 182 of 1007
ENGINE - K SERIES KV6
REPAIRS 12-3-5
12.Fit LH camshaft rear timing belt.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft rear timing belt - LH cylinder
head.
13.Top-up engine oil.
+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.
14.Connect battery earth lead.
Camshafts - RH cylinder head
$% 12.13.03
Remove
1.Disconnect battery earth lead.
2.Remove camshaft timing belt.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
3.Remove RH rear camshaft timing belt.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft rear timing belt - RH cylinder
head.
4.Remove RH camshaft cover gasket.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - RH.
5.Remove 4 bolts securing RH front timing belt
cover backplate to cylinder head and remove
backplate.
6.Remove 2 bolts securing RH rear timing belt
cover backplate and remove backplate.
M12 6903
M12 6904