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
Page 183 of 1007
ENGINE - K SERIES KV6
12-3-6 REPAIRS
7.Using sequence shown, progressively loosen
22 bolts securing camshaft carrier to cylinder
head until valve spring pressure is released
and remove bolts.
8.Release camshaft carrier from dowels and
remove carrier.
9.Remove both camshafts and discard oil seals.
10.Using a stick magnet, remove 12 hydraulic
tappets from cylinder head.
CAUTION: Store hydraulic tappets in their
fitted order and store upright. Maintain
absolute cleanliness when handling
hydraulic tappets. Failure to observe these
precautions can result in engine failure.
11.Clean camshafts and bearing running surfaces
in camshaft carrier and cylinder head.
12.Inspect camshafts and replace camshafts if
scored, pitted or excessively worn.
Note: Camshafts are colour coded - Inlet -
ORANGE; Exhaust - BLUE.Refit
1.Thoroughly clean and lubricate hydraulic
tappets with clean engine oil. Fit hydraulic
tappets to original bores in cylinder head.
2.Ensure that mating faces of camshaft carrier
and cylinder head are clean and dry.
3.Lubricate camshafts and bearing journals with
clean engine oil.
4.Position camshafts in cylinder head with rear
timing gear drive slots in each camshaft facing
towards the centre as shown.
CAUTION: Ensure camshafts are in their
correct fitted locations, camshafts are
colour coded - Inlet - ORANGE, Exhaust -
BLUE.
5.Apply continuous thin beads of sealant, Part
No. STC 4600, to paths on camshaft carrier as
shown. Spread sealant to an even film using a
roller.
Ensure sealant does not enter oil feed holes
or grooves and that assembly is completed
within 20 minutes.
Page 184 of 1007
ENGINE - K SERIES KV6
REPAIRS 12-3-7
6.Position camshaft carrier, fit and progressively
tighten bolts in the sequence shown to 10 Nm
(7.5 lbf.ft).
7.Noting that the front camshaft oil seals are
black in colour and the rear oil seals are red, fit
new camshaft oil seals using LRT-12-203 and
LRT-12-148A
CAUTION: Oil seals must be fitted dry. Do
not use tool LRT-12-148 for fitting seals. 8.Clean camshaft timing cover backplate bolts
and apply sealant, Part No. STC 50552 to first
3 threads.
9.Fit camshaft cover backplates fit and tighten
bolts to 9 Nm (7 lbf.ft).
10.Fit RH camshaft cover gasket.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - RH.
11.Fit camshaft timing belt.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
12.Fit RH rear camshaft timing belt.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft rear timing belt - RH cylinder
head.
13.Top-up engine oil.
+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.
14.Connect battery earth lead.
Page 185 of 1007
ENGINE - K SERIES KV6
12-3-8 REPAIRS
Inlet camshaft front oil seal
$% 12.13.40
Remove
1.Remove camshaft timing belt.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
2.Remove camshaft oil seal using LRT- 12-147
and centre bolt LRT-12-129.
3.Remove and discard oil seal from LRT-12-147.Refit
1.Clean oil seal recess and camshaft.
2.Ensure oil seal protector sleeve LRT-12-203, is
clean. Fit sleeve to camshaft.
3.Position oil seal and using LRT-12-148A, drift
seal into position.
CAUTION: Oil seal must be fitted dry. Do not
use tool LRT-12-148 for fitting seal.
4.Remove seal protector, LRT-12-203, from end
of camshaft.
5.Fit camshaft timing belt.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
6.Top-up engine oil.
+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.
Page 186 of 1007
ENGINE - K SERIES KV6
REPAIRS 12-3-9
Camshaft rear oil seal
$% 12.13.42
Remove
1.Disconnect battery earth lead.
2. LH bank only: Remove LH rear camshaft
timing belt.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft rear timing belt - LH cylinder
head.
3. RH bank only:Remove RH rear camshaft
timing belt.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft rear timing belt - RH cylinder
head.
4.Remove camshaft rear oil seal using LRT-12-
147 and the centre bolt from LRT-12-129.
5.Remove and discard oil seal from LRT-12-147.Refit
1.Clean oil seal recess and camshaft.
2.Ensure oil seal protector sleeve LRT-12-203, is
clean. Fit sleeve to camshaft.
3.Position oil seal and using LRT-12-148A, drift
seal into position.
CAUTION: Do not use tool LRT-12-148 for
fitting seal.
4.Remove seal protector, LRT-12-203, from end
of camshaft.
5. LH bank only: Fit LH rear camshaft timing belt.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft rear timing belt - LH cylinder
head.
6. RH bank only: Fit RH rear camshaft timing
belt.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft rear timing belt - RH cylinder
head.
7.Connect battery earth lead.
8.Top-up engine oil.
+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.
Page 188 of 1007
ENGINE - K SERIES KV6
REPAIRS 12-3-11
Crankshaft front oil seal
$% 12.21.14
Remove
1.Disconnect battery earth lead.
2.Remove camshaft timing belt.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
3.Remove crankshaft gear.
4.Fit thrust button, LRT-12-200/3 to end of
crankshaft.
5.Screw LRT-12-200 into crankshaft front oil
seal.
6.Tighten centre bolt of LRT-12-200 t o r e m o v e o i l
seal.
7.Remove and discard oil seal from special tool.
8.Remove thrust button from crankshaft.Refit
1.Clean oil seal recess in oil pump and running
surface on crankshaft, ensure bolt holes are
clean and dry.
2.Fit oil seal guide, from seal kit, over end of
crankshaft.
3.Position new seal on crankshaft up against oil
pump housing. Drift seal into place using tool
LRT-12-202.
4.Remove LRT-12-202 and oil seal guide from
crankshaft.
5.Fit gear to crankshaft.
6.Fit camshaft timing belt.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
7.Connect battery earth lead.
8.Top-up engine oil.
+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.
Page 190 of 1007
ENGINE - K SERIES KV6
REPAIRS 12-3-13
Cylinder head gasket - LH
$% 12.29.02
Remove
1.Disconnect battery earth lead.
2.Drain cooling system.
+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
3.Remove inlet manifold chamber.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.
4.Remove LH exhaust manifold gasket.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket - exhaust
manifold - LH - Non NAS.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket(s) -
exhaust manifold - LH - NAS.
5.Remove camshaft timing belt.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
6.Remove 4 bolts securing LH front camshaft
timing belt cover backplate to cylinder head;
remove backplate.
7.Remove LH camshaft cover gasket.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - LH - Up to 03MY.8.Remove 3 nuts and 3 bolts securing ignition
coils to LH inlet manifold and release coil earth
lead, if fitted.
9.Remove ignition coils and position aside, if
fitted.
10.Release clip and disconnect coolant bleed
hose from inlet manifold and move hose aside.
11.Depress locking collar and release breather
hose from LH inlet manifold.
Page 192 of 1007
ENGINE - K SERIES KV6
REPAIRS 12-3-15
Refit
1.Clean cylinder head mating face.
CAUTION: Use suitable gasket removal
spray and a plastic scraper.
2.Remove bolts securing cylinder liner clamps
LRT-12-144 to cylinder block and remove
clamps.
CAUTION: Do not rotate crankshaft.
3.Clean cylinder block face and dowel holes.
4.Clean cylinder head bolts and wipe dry.
5.Lightly lubricate threads and beneath heads of
cylinder head bolts with clean engine oil.
6.Check that fitted height of dowels is between 10
to 11 mm (0.40 to 0.43 in) above cylinder block
top face. Replace dowels if fitted height is
incorrect.
7.Fit new cylinder head gasket onto cylinder
block with the word 'TOP' uppermost.
8.With assistance, fit cylinder head and carefully
position LH inlet to RH inlet manifold.
9.Carefully enter cylinder head bolts, DO NOT
DROP. Screw bolts into place by hand.10.Tighten cylinder head bolts progressively in the
sequence shown to :
lStage 1 - 25 Nm (18 lbf.ft)
lStage 2 - Tighten in the same sequence to
25 Nm (18 lbf.ft)
lStage 3 -Tighten in the same sequence to
25 Nm (18 lbf.ft)
lStage 4 - Using an angle torque gauge,
tighten bolts in the same sequence a further
180°
11.Fit LH camshaft cover gasket.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - LH - Up to 03MY.
12.Remove and discard 'O' rings from injectors.
13.Clean injectors and injector locations in fuel rail.
14.Lubricate new 'O' rings with castor oil and fit to
injectors.
15.Position fuel rail assembly and secure injectors
to inlet manifolds.
16.Position injector protection cover - if fitted to RH
fuel rail and secure injector harness to
protection cover or fuel rail with clips.
17.Fit bolts securing fuel rail to inlet manifolds and
tighten to 9 Nm (7 lbf.ft).
18.Position CMP sensor bracket, fit and tighten
bolt to 9 Nm (7 lbf.ft).
19.Connect CMP sensor multiplug and secure to
bracket.
20.Connect breather hose to LH inlet manifold.
21.Connect coolant bleed hose to inlet manifold
and secure with clip.
22.Position ignition coils to LH inlet manifold.
23.Position earth lead, fit nuts and bolts securing
ignition coils to LH inlet manifold and tighten to
9 Nm (7 lbf.ft).
24.Position ht lead guide bracket, fit and tighten
special bolt.
25.Connect ht leads to spark plugs and secure ht
leads in guide clips.
26.Clean camshaft timing belt cover backplate
bolts and apply sealant, Part No. STC 50552 to
the first 3 threads.
