Page 235 of 1007

ENGINE - K SERIES KV6
12-3-58 REPAIRS
Camshaft timing belt
$% 12.65.18
Remove
1.Disconnect battery earth lead.
2.Remove ancillary drive belt.
+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - KV6.
3.Remove RH front road wheel.
4.Remove 3 bolts securing RH splash shield to
body and remove shield.
5.Remove 3 bolts securing camshaft timing belt
LH rear cover and remove cover.
6.Remove inlet manifold chamber.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - from 03MY.7.Remove 2 bolts securing RH rear timing belt
cover heat shield; remove heat shield.
8.Remove 3 bolts securing RH rear timing belt
cover; remove cover.
9.Using a socket on crankshaft pulley bolt, rotate
crankshaft in a clockwise direction. Align the
engine "SAFE" position, notch on crankshaft
pulley with the "ARROW" on front mounting
plate and the timing marks aligned on the rear
camshaft gears as illustrated.
CAUTION: Do not use camshaft gear bolts
or timing belt to rotate crankshaft.
M12 6614
M12 6694
Page 243 of 1007

ENGINE - K SERIES KV6
12-3-66 REPAIRS
40.Fit bolt and nut and bolt securing alternator to
front mounting plate and tighten to 45 Nm (33
lbf.ft).
41.Connect alternator multiplug.
42.Connect battery lead to alternator, fit and
tighten nut to 8 Nm (6 lbf.ft), fit terminal cover.
43.Position PAS pump to front mounting plate, fit
and tighten bolts to 25 Nm (18 lbf.ft).
44.Position PAS pipe to engine front mounting
plate, fit and tighten bolt to 25 Nm (18 lbf.ft).
45.Clean PAS pump pulley mating faces.
46.Position PAS pump pulley, fit and tighten Torx
screws to 9 Nm (7 lbf.ft).
47.Position lower engine steady to sump
mounting, fit and tighten bolt to 100 Nm (74
lbf.ft).
48.Tighten bolt securing lower engine steady to
subframe to 100 Nm (74 lbf.ft).
49.Clean LH rear timing belt cover.
50.Position LH rear timing belt cover, fit and
tighten bolts to 4 Nm (3 lbf.ft).
51.Clean RH rear timing belt cover.
52.position RH rear timing belt cover, fit bolts and
tighten to 4 Nm (3 lbf.ft).
53.Position heat shield, fit bolts and tighten M6 bolt
to 9 Nm (7 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).
54.Fit inlet manifold chamber.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - from 03MY.
55.Fit RH road wheel and tighten nuts to 115 Nm
(85 lbf.ft).
56.Fit ancillary drive belt.
+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - KV6.
Camshaft timing belt cover - RH front
$% 12.65.39
Remove
1.Disconnect battery earth lead.
2.Remove ancillary drive belt.
+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - KV6.
3.Remove 3 bolts securing camshaft timing belt
RH front cover and remove cover.
Refit
1.Clean RH front timing belt cover.
2.Position RH front timing belt cover, fit and
tighten bolts to 4 Nm (3 lbf.ft).
3.Fit ancillary drive belt.
+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - KV6.
4.Connect battery earth lead.
Page 246 of 1007

ENGINE - K SERIES KV6
REPAIRS 12-3-69
Camshaft rear timing belt - LH cylinder
head
$% 12.65.56
Remove
1.Disconnect battery earth lead.
2.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Remove LH rear timing belt cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt cover - LH rear.
4.Remove RH front road wheel.
5.Remove 3 bolts securing RH splash shield to
body and remove shield.6.Using a socket on crankshaft pulley bolt, rotate
crankshaft in a clockwise direction. Align the
engine "SAFE" position, notch on crankshaft
pulley aligned to the "ARROW" on front
mounting plate and the timing marks aligned on
the rear camshaft gears as illustrated.
CAUTION: Do not use camshaft gear bolts
or timing belt to rotate crankshaft. Never
use the arrow on the oil pump body as a
timing reference.
7.Insert timing pin LRT-12-232 through hole in
lower crankcase, ensuring pin is located in hole
in drive plate.
CAUTION: Hole immediately adjacent to
side of lower crankcase must be used.
M12 6614
LRT-12-232
M12 7927
Page 249 of 1007
ENGINE - K SERIES KV6
12-3-72 REPAIRS
9.Position LRT-12-197 into the front end of the
LH exhaust camshaft.
10.With assistance, using a 30 mm socket on LRT-
12-197, turn the LH exhaust camshaft
sufficiently to align camshaft gears to the drive
slots in each camshaft.
11.Remove LRT-12-198 alignment pins and fit
new camshaft gear retaining bolts.
12.Tighten camshaft gear bolts to:
lStage 1 - 27 Nm (20 lbf.ft)
lStage 2 - Further 90°
13.Remove LRT-12-175 from camshaft gears.
14.Remove LRT-12-197 from front end of exhaust
camshaft.15.Clean LH exhaust camshaft cap seal recess
and fit new cap seal.
16.Remove timing pin LRT-12-232 from lower
crankcase.
17.Fit splash shield and secure with bolts.
18.Fit RH road wheel and tighten nuts to 115 Nm
(85 lbf.ft).
19.Fit LH rear timing belt cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt cover - LH rear.
20.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
21.Connect battery earth lead.
Page 250 of 1007

ENGINE - K SERIES KV6
REPAIRS 12-3-73
Camshaft rear timing belt - RH cylinder
head
$% 12.65.57
Remove
1.Disconnect battery earth lead.
2.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Remove RH front road wheel.
4.Remove 3 bolts securing RH splash shield to
body and remove shield.
5.Remove RH rear timing belt cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt cover - RH rear.6.Using a socket on crankshaft pulley bolt, rotate
crankshaft in a clockwise direction. Align the
engine "SAFE" position, notch on crankshaft
pulley aligned to the "ARROW" on front
mounting plate and the timing marks aligned on
the rear camshaft gears as illustrated.
CAUTION: Do not use camshaft gear bolts
or timing belt to rotate crankshaft. Never
use the arrow on the oil pump body as a
timing reference.
7.Insert timing pin LRT-12-232 through hole in
lower crankcase, ensuring pin is located in hole
in drive plate.
CAUTION: Hole immediately adjacent to
side of lower crankcase must be used.
M12 6614
LRT-12-232
M12 7927
Page 253 of 1007

ENGINE - K SERIES KV6
12-3-76 REPAIRS
7.Fit LRT-12-198 alignment pins into the end of
each camshaft.
8.Position timing belt and gears over LRT-12-198
and locate gears onto camshafts.
9.Position LRT-12-197 into the front end of the
RH exhaust camshaft.
10.With assistance, using a 30 mm socket on LRT-
12-197, turn the RH exhaust camshaft
sufficiently to align camshaft gears to the drive
slots in each camshaft.11.Remove LRT-12-198 alignment pins and fit
new camshaft gear retaining bolts.
12.Tighten camshaft gear bolts to:
lStage 1 - 27 Nm (20 lbf.ft)
lStage 2 - Further 90°
13.Remove LRT-12-175 from camshaft gears.
14.Remove LRT-12-197 from front end of exhaust
camshaft.
15.Clean RH exhaust camshaft cap seal recess
and fit new cap seal.
16.Remove timing pin LRT-12-232 from lower
crankcase.
17.Fit splash shield and secure with bolts.
18.Fit RH road wheel and tighten nuts to 115 Nm
(85 lbf.ft).
19.Fit RH rear timing belt cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt cover - RH rear.
20.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
21.Connect battery earth lead.
Page 296 of 1007

EMISSION CONTROL
REPAIRS 17-1-5
Charcoal canister - NAS
$% 17.15.13
Remove
1.Disconnect battery earth lead.
2.Remove RH rear wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
3.Release and disconnect pipes from charcoal
canister and DMTL.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
4.Remove 2 bolts securing canister support
bracket and release assembly from mounting.
5.Disconnect multiplug from DMTL and remove
canister and valve assembly.6.Release clip and disconnect hose from
charcoal canister.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
7.Remove nut and bolt securing charcoal
canister and remove canister from bracket.
Refit
1.Fit charcoal canister to bracket and tighten nut
and bolt to 4 Nm (3 lbf.ft).
2.Connect hose and secure with clip.
3.Position canister assembly and connect
multiplug.
4.Fit canister assembly to mounting and tighten
bolts to 4 Nm (3 lbf.ft).
5.Connect pipes to DMTL and canister.
6.Fit wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
7.Connect battery earth lead.
Page 302 of 1007

EMISSION CONTROL
REPAIRS 17-1-11
Module - tank leakage diagnostic (DMTL)
$% 17.45.41
Remove
1.Disconnect battery earth lead.
2.Remove RH rear wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
3.Release and disconnect pipes from charcoal
canister and DMTL.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
4.Remove 2 bolts securing canister support
bracket and release assembly from mounting.
5.Disconnect multiplug from DMTL and remove
canister and valve assembly.6.Release clip and disconnect hose from DMTL.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
7.Remove 3 screws and remove DMTL.
Refit
1.Fit DMTL and secure with screws.
2.Connect hose and secure with clip.
3.Position canister assembly and connect
multiplug.
4.Fit canister assembly to mounting and tighten
bolts to 4 Nm (3 lbf.ft).
5.Connect pipes to DMTL and canister.
6.Fit wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
7.Connect battery earth lead.