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.
Page 303 of 1007
EMISSION CONTROL
17-1-12 REPAIRS
Filter - fuel leak detection pump - KV6 -
NAS
$% 17.45.42
Remove
1.Disconnect battery earth lead.
2.Remove RH rear wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
3.Remove nut and release filter from bracket.
4.Release clip and remove filter from pipe.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
Refit
1.Fit filter to pipe and secure with clip.
2.Fit filter to bracket and tighten nut to 3 Nm (2.2
lbf.ft).
3.Fit wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
4.Connect battery earth lead.
Catalytic converter - RH - KV6 - NAS
$% 17.50.01
Remove
1.Position vehicle on 4 post ramp.
2.Disconnect battery earth lead.
3.Remove engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
4.Release pre catalyst H02S harness from clips.
5.Release and disconnect HO2S multiplug.
6.Remove intermediate pipe and silencer.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Intermediate
pipe - NAS.
7.Remove 3 bolts and remove LH heat shield.
M19 3484
Page 336 of 1007
FUEL DELIVERY SYSTEM - PETROL
REPAIRS 19-2-15
Sensor - heated oxygen (H02S) - pre-
catalyst - RH - KV6 - Non NAS
$% 19.22.17
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove LH front road wheel.
3.Release RH HO2S multiplug from coolant rail
bracket and disconnect multiplug.
4.Remove HO2S from RH exhaust manifold.Refit
1.Clean HO2S and exhaust manifold mating
face.
2.Fit HO2S and tighten to 55 Nm (41 lbf.ft).
3.Connect RH HO2S multiplug, secure multiplug
in coolant rail bracket.
4.Fit LH front road wheel and tighten nuts to 115
Nm (85 lbf.ft).
5.Remove stands and lower vehicle.
M30 0996
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.
Page 352 of 1007
FUEL DELIVERY SYSTEM - PETROL
REPAIRS 19-2-31
13.With assistance, remove 4 bolts securing fuel
tank to body and remove tank.
NOTE: Pull vent and breather hoses through
body while lowering fuel tank.
14.Remove fuel tank from cradle. Collect heat and
fire shields.
15.Remove clips from breather hose and vent
pipes.
16.Disconnect breather hose and vent pipes from
fuel tank.Refit
1.Connect breather hose and vent pipes to fuel
tank, secure with clips.
2.Position heat and fire shields. Fit cradle to fuel
tank.
3.With assistance, fit bolts securing fuel tank to
body and tighten to 45 Nm (33 lbf.ft).
NOTE: Pass vent and breather hoses through
body while fitting tank.
4.Raise subframe, fit bolts and tighten to 190 Nm
(140 lbf.ft).
5.Connect breather hose to filler neck, fit and
secure clip.
6.Connect vent hose to vapour separator, fit and
secure clip.
7.Fit RH rear wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
8.Fit propeller shaft.
+ DRIVESHAFTS, REPAIRS, Propeller
shaft assembly.
9.Fit 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.
10.Fit fuel pump assembly.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Pump - fuel.
11.Connect battery earth lead.
Page 353 of 1007
FUEL DELIVERY SYSTEM - PETROL
19-2-32 REPAIRS
Tank - NAS
$% 19.55.01
Remove
1.Position vehicle on ramp.
2.Disconnect battery earth lead.
3.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.
+ FUEL DELIVERY SYSTEM -
PETROL, ADJUSTMENTS, Fuel tank - drain.
WARNING: The fuel tank must be drained
before it is removed from the vehicle.
4.Remove intermediate exhaust pipe.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Intermediate
pipe - NAS.
5.Remove propeller shaft.
+ DRIVESHAFTS, REPAIRS, Propeller
shaft assembly.
6.Remove RH rear wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
7.Remove tamper proof cover from filler hose clip
and loosen clip.8.Support weight of rear subframe and remove 4
bolts securing subframe to body.
9.Lower subframe.
CAUTION: Do not allow sub frame to hang
on rear brake hoses.
10.With assistance, remove 4 bolts securing fuel
tank to body and remove tank.
NOTE: Pull vent and breather hoses through
body while lowering fuel tank.
Page 354 of 1007
FUEL DELIVERY SYSTEM - PETROL
REPAIRS 19-2-33
11.Remove fuel tank from cradle. Collect heat and
fire shields.
12.Remove clips from breather hose and vent
pipes.
13.Disconnect breather hose and vent pipe from
fuel tank.Refit
1.Connect breather hose and vent pipe to tank,
secure with clips.
2.Position heat and fire shields. Fit cradle to fuel
tank.
3.With assistance, fit bolts securing fuel tank to
body and tighten to 45 Nm.
NOTE: Pass vent and breather hoses through
body while fitting tank.
4.Raise subframe, fit bolts and tighten to 190 Nm.
5.Connect breather hose to filler neck, fit and
secure clip.
6.Fit RH rear wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
7.Fit propeller shaft.
+ DRIVESHAFTS, REPAIRS, Propeller
shaft assembly.
8.Fit intermediate exhaust pipe.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Intermediate
pipe - NAS.
9.Fit fuel pump assembly.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Pump - fuel.
10.Connect battery earth lead.
Page 355 of 1007
FUEL DELIVERY SYSTEM - PETROL
19-2-34 REPAIRS
Filler neck
$% 19.55.07
Remove
1.Disconnect battery earth lead.
2.Ensure fuel tank is less than half full. If not,
drain fuel tank to less than half full.
+ FUEL DELIVERY SYSTEM -
PETROL, ADJUSTMENTS, Fuel tank - drain.
3.Remove RH rear wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
4.Remove fuel filler cap.
CAUTION: Before disconnecting any part of
the fuel system, it is imperative that all dust,
dirt and debris is removed from around
components to prevent ingress of foreign
matter into fuel system.
5.Unclip escutcheon from fuel filler neck.
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.
6.Remove 3 nuts securing fuel filler neck to body.7.Release clip from breather hose and
disconnect breather hose from filler neck.
8.Release fuel tank vent pipe from filler neck.
9.Disconnect Lucar connector from fuel filler
neck.
10.Remove bolt securing filler neck to body.
11.Remove tamper proof cover from filler hose clip
and loosen clip.
12.Disconnect hose from filler neck and remove
filler neck assembly.
Refit
1.Position filler neck assembly, connect to hose,
secure clip and fit tamper proof cover.
2.Fit bolt securing filler neck to body and tighten
to 9 Nm (7 lbf.ft).
3.Connect Lucar connector to fuel filler neck.
4.Position fuel tank vent pipe around filler neck.
5.Connect breather hose to filler neck, fit and
secure clip.
6.Fit nuts securing fuel filler neck to body and
tighten to 9 Nm (7 lbf.ft).
7.Clip escutcheon to fuel filler neck.
8.Fit fuel filler cap.
9.Fit RH rear wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
10.Connect battery earth lead.
M19 3230
