10-Engine - K Series Kv6
10-Engine - K Series Kv6
10-Engine - K Series Kv6
$% 12.90.09.01
Check
1. Remove oil pressure switch.
+
ENGINE - K SERIES KV6, REPAIRS,
Switch - oil pressure.
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2. Fit sealing washer from oil pressure switch to
LRT-12-052/10 oil pressure gauge adaptor.
3. Fit and tighten oil pressure gauge adaptor LRT-
12-052/10 to oil pump housing.
4. Connect oil pressure gauge LRT-12-052C and
tighten union.
5. Check and if necessary top up engine oil.
6. Start and run engine until normal operating
temperature is reached.
7. Note oil pressure readings with the engine
running at idle and at 3000 rev/min.
+
GENERAL DATA, Engine – KV6
Petrol.
8. Switch off engine, unscrew gauge union and
remove gauge.
9. Remove adaptor.
10. Wipe off oil spillage
11. Fit oil pressure switch.
+
ENGINE - K SERIES KV6, REPAIRS,
Switch - oil pressure.
12. Recheck engine oil and top up if necessary.
ADJUSTMENTS 12-3-1
ENGINE - K SERIES KV6
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12-3-2 ADJUSTMENTS
ENGINE - K SERIES KV6
REPAIRS
$% 12.13.02
Remove
1. Disconnect battery earth lead.
2. Remove camshaft timing belt.
+
ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
3. Remove LH camshaft rear timing belt.
+
ENGINE - K SERIES KV6, REPAIRS,
Camshaft rear timing belt - LH cylinder
head.
4. Remove LH camshaft cover gasket.
+
ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - LH. 7. Using sequence shown, progressively loosen
22 bolts securing camshaft carrier to cylinder
head until valve spring pressure is released,
remove bolts.
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8. Release camshaft carrier from dowels and
remove carrier.
M12 6905
REPAIRS 12-3-3
ENGINE - K SERIES KV6
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.
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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.
12-3-4 REPAIRS
ENGINE - K SERIES KV6
13. Top-up engine oil.
+ MAINTENANCE, MAINTENANCE, Camshafts - RH cylinder head
Engine Oil and Filter – KV6.
14. Connect battery earth lead. $% 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.
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M12 6903
M12 6904
REPAIRS 12-3-5
ENGINE - K SERIES KV6
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.
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8. Release camshaft carrier from dowels and
remove carrier.
12-3-6 REPAIRS
ENGINE - K SERIES KV6
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.
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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.
REPAIRS 12-3-7
ENGINE - K SERIES KV6
5. Fit camshaft timing belt.
Inlet camshaft front oil seal + ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
$% 12.13.40 6. Top-up engine oil.
+ MAINTENANCE, MAINTENANCE,
Remove Engine Oil and Filter – KV6.
1. Remove camshaft timing belt.
+ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
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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.
12-3-8 REPAIRS
ENGINE - K SERIES KV6
3. Position oil seal and using LRT-12-148A, drift
Camshaft rear oil seal seal into position.
CAUTION: Do not use tool LRT-12-148 for
$% 12.13.42 fitting seal.
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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.
REPAIRS 12-3-9
ENGINE - K SERIES KV6
Pulley - crankshaft
$% 12.21.01
Remove
1. Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
2. Remove RH front road wheel.
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bolt.
7. Remove tools from crankshaft pulley, remove
crankshaft pulley.
M12 6614
Refit
1. Clean crankshaft pulley and crankshaft gear
3. Remove 3 bolts securing RH splash shield to mating faces.
body and remove shield. 2. Fit crankshaft pulley to crankshaft gear and
ensure that the indent on pulley locates over
the lug on crankshaft gear.
3. 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).
4. Remove tools from crankshaft pulley.
5. Ensure drive belt is located on ancillary pulleys,
raise belt tensioner and fit drive belt to
crankshaft pulley.
6. Fit splash shield and secure with bolts.
7. Fit RH road wheel and tighten nuts to 115 Nm
(85 lbf.ft)
8. Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
4. Using a 3/8 square drive socket bar, raise
ancillary drive belt tensioner and release drive
belt from crankshaft pulley.
12-3-10 REPAIRS
ENGINE - K SERIES KV6
Refit
Crankshaft front oil seal 1. Clean oil seal recess in oil pump and running
surface on crankshaft, ensure bolt holes are
$% 12.21.14 clean and dry.
2. Fit oil seal guide, from seal kit, over end of
Remove crankshaft.
1. Disconnect battery earth lead.
2. Remove camshaft timing belt.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
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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
3. Remove crankshaft gear. 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.
REPAIRS 12-3-11
ENGINE - K SERIES KV6
$% 12.21.20
Remove
1. Remove torque converter drive plate.
+ ENGINE - K SERIES KV6, REPAIRS,
Torque converter drive plate.
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6. Fit torque converter drive plate.
+ ENGINE - K SERIES KV6, REPAIRS,
Torque converter drive plate.
7. Check engine oil level, top-up if necessary.
+ MAINTENANCE, MAINTENANCE,
2. Remove and discard 5 bolts securing Engine Oil and Filter – KV6.
crankshaft rear oil seal to cylinder block.
3. Remove and discard crankshaft rear oil seal.
Refit
1. Clean cylinder block face and oil seal running
surface on crankshaft; ensure bolt holes are
clean and dry.
12-3-12 REPAIRS
ENGINE - K SERIES KV6
$% 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.
4. Remove LH exhaust manifold gasket.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket - exhaust 8. Remove 3 nuts and 3 bolts securing ignition
manifold - LH - Non NAS. coils to LH inlet manifold and release coil earth
+ MANIFOLDS & EXHAUST SYSTEMS lead.
- K SERIES KV6, REPAIRS, Gasket(s) - 9. Remove ignition coils and position aside.
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exhaust manifold - LH - NAS.
5. Remove camshaft timing belt.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
REPAIRS 12-3-13
ENGINE - K SERIES KV6
12. Disconnect clips securing RH injector harness 14. Remove 2 bolts securing fuel rail to LH inlet
to injector protection cover - if fitted or from manifold.
bosses on fuel rail. 15. Release injectors from manifolds and carefully
lay fuel rail and injectors aside.
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CAUTION: Always fit plugs to open
connections to prevent contamination.
12-3-14 REPAIRS
ENGINE - K SERIES KV6
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block with the word 'TOP' uppermost.
Refit
9. With assistance, fit cylinder head and carefully
1. Clean cylinder head mating face.
position LH inlet to RH inlet manifold.
CAUTION: Use suitable gasket removal 10. Carefully enter cylinder head bolts, DO NOT
spray and a plastic scraper. DROP. Screw bolts into place by hand.
REPAIRS 12-3-15
ENGINE - K SERIES KV6
16. Position fuel rail assembly and secure injectors
to inlet manifolds. Cylinder head gasket - RH
17. Position injector protection cover - if fitted to RH
fuel rail and secure injector harness to $% 12.29.03
protection cover or fuel rail with clips.
18. Fit bolts securing fuel rail to inlet manifolds and Remove
tighten to 9 Nm (7 lbf.ft). 1. Disconnect battery earth lead.
19. Position CMP sensor bracket, fit and tighten 2. Drain cooling system.
bolt to 9 Nm (7 lbf.ft).
20. Connect CMP sensor multiplug and secure to
+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
bracket. 3. Remove inlet manifold chamber.
21. Connect breather hose to LH inlet manifold.
22. Connect coolant bleed hose to inlet manifold
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
and secure with clip. manifold chamber.
23. Position ignition coils to LH inlet manifold. 4. Remove RH exhaust manifold gasket.
24. Position earth lead, fit nuts and bolts securing
ignition coils to LH inlet manifold and tighten to
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket - exhaust
9 Nm (7 lbf.ft). manifold - RH - Non NAS.
25. Position ht lead guide bracket, fit and tighten
special bolt.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket(s) -
26. Connect ht leads to spark plugs and secure ht
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exhaust manifold - RH - KV6 - NAS.
leads in guide clips. 5. Remove camshaft timing belt.
27. Clean camshaft timing belt cover backplate
bolts and apply Loctite 242 to the first 3 threads.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
28. Position backplate, fit and tighten bolts to 9 Nm.
29. Fit camshaft timing belt.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
30. Fit 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.
31. Fit inlet manifold chamber.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber.
32. Fill cooling system.
+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill. 6. Remove 4 bolts securing RH front timing belt
33. Check engine oil level and top-up if necessary. cover backplate to cylinder head and remove
+ MAINTENANCE, MAINTENANCE, backplate.
Engine Oil and Filter – KV6.
12-3-16 REPAIRS
ENGINE - K SERIES KV6
7. Depress locking collar and release breather 10. Release injector harness clips from injector
hose from RH inlet manifold. protection cover - if fitted or from bosses on fuel
8. Remove RH camshaft cover gasket. rail.
+ ENGINE - K SERIES KV6, REPAIRS,
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Camshaft cover gasket - RH.
REPAIRS 12-3-17
ENGINE - K SERIES KV6
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CAUTION: Always fit plugs to open
Refit
connections to prevent contamination.
1. Clean cylinder head mating face.
CAUTION: Use suitable gasket removal
spray and a plastic scraper.
16. Remove and discard cylinder head gasket. 3. Clean cylinder block mating face and dowel
17. Remove and discard 2 cylinder head locating holes.
dowels. 4. Clean cylinder head bolts and wipe dry.
5. Lightly lubricate threads and beneath heads of
Note: Replacement dowels are supplied with
cylinder head bolts with clean engine oil.
new cylinder head gasket.
6. Fit 2 new locating dowels supplied with
replacement cylinder head gasket.
CAUTION: Do not rotate crankshaft whilst
LH cylinder head is fitted.
12-3-18 REPAIRS
ENGINE - K SERIES KV6
15. Lubricate new 'O' rings with castor oil and fit to
injectors.
16. Position fuel rail assembly and secure injectors
to inlet manifolds.
17. Position injector protection cover - if fitted to RH
fuel rail; secure injector harness to protection
cover or fuel rail with clips.
18. Fit bolts securing fuel rail to inlet manifolds and
tighten to 9 Nm (7 lbf.ft).
19. Connect coolant bleed hose to inlet manifold
and secure with clip.
20. Connect breather hoses to RH camshaft cover
and inlet manifold.
21. Position ignition coils to LH inlet manifold.
22. Position earth lead, fit nuts and bolts securing
ignition coils to LH inlet manifold and tighten to
9 Nm (7 lbf.ft).
7. Check that fitted height of dowels is between 10
23. Connect multiplugs to plug top coils and secure
to 11 mm (0.40 to 0.43 in) above cylinder block
with locking clips.
top face.
24. Clean camshaft timing belt cover backplate
8. Fit new cylinder head gasket onto cylinder
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bolts and apply Loctite 242 to the first 3 threads.
block with the word 'TOP' uppermost.
25. Position backplate, fit and tighten bolts to 9 Nm
9. With assistance, fit cylinder head and carefully
(7 lbf.ft).
position RH inlet to LH inlet manifold.
26. Fit camshaft timing belt.
10. Carefully enter cylinder head bolts, DO NOT
DROP. Screw bolts into place by hand.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
27. Fit RH exhaust manifold gasket.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket - exhaust
manifold - RH - Non NAS.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket(s) -
exhaust manifold - RH - KV6 - NAS.
28. Fit inlet manifold chamber.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber.
29. Fill cooling system.
+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
30. Check engine oil level and top-up if necessary.
11. Tighten cylinder head bolts progressively in the + MAINTENANCE, MAINTENANCE,
sequence illustrated to: Engine Oil and Filter – KV6.
l Stage 1 - 25 Nm (18 lbf.ft)
l Stage 2 - Tighten in the same sequence to
25 Nm (18 lbf.ft)
l Stage 3 -Tighten in the same sequence to
25 Nm (18 lbf.ft)
l Stage 4 - Using an angle torque gauge,
tighten bolts in the same sequence a further
180°
12. Fit RH camshaft cover gasket.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - RH.
13. Remove and discard lower 'O' rings from
injectors.
14. Clean injectors and injector locations in fuel rail.
REPAIRS 12-3-19
ENGINE - K SERIES KV6
$% 12.29.40
Remove
1. Remove engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
Refit
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1. Clean mating surfaces of camshaft cover and
carrier.
2. Clean inside of camshaft cover. If necessary,
wash oil separator elements in solvent and
blow dry.
3. Position new gasket to camshaft carrier with
2. Depress locking collars and release 2 breather
arrows on gasket pointing towards inlet
hoses from LH camshaft cover.
manifold.
3. Disconnect 3 ht leads from spark plugs.
4. Remove special bolt securing ht lead guide
bracket to LH cylinder head and position ht
leads aside.
5. Disconnect CMP sensor multiplug and release
male end of multiplug from bracket.
6. Remove bolt securing multiplug bracket which
also retains front HO2S multiplug, move
bracket and multiplug aside.
12-3-20 REPAIRS
ENGINE - K SERIES KV6
8. Position ht lead guide bracket, fit and tighten
special bolt. Camshaft cover gasket - RH
9. Connect breather hoses to LH camshaft cover.
10. Fit engine acoustic cover. $% 12.29.41
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic. Remove
11. Check engine oil, top-up if necessary. 1. Remove inlet manifold chamber.
+ MAINTENANCE, MAINTENANCE, + MANIFOLDS & EXHAUST SYSTEMS
Engine Oil and Filter – KV6. - K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber.
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2. Depress locking collar and release breather
hose from RH camshaft cover.
REPAIRS 12-3-21
ENGINE - K SERIES KV6
Refit
1. Clean mating surfaces of camshaft cover and
carrier.
2. Position new gasket to camshaft carrier with
arrows on gasket pointing towards inlet
manifold.
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3. Position camshaft cover, fit and tighten bolts
progressively in the sequence shown to 9 Nm
(7 lbf.ft).
4. Position plug top coils, fit bolts and tighten to 9
Nm (7 lbf.ft).
5. Position earth lead to RH camshaft cover, fit
bolt and tighten to 9 Nm (7 lbf.ft).
6. Secure breather hose to camshaft cover.
7. Fit inlet manifold chamber.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber.
8. Check engine oil, top-up if necessary.
5. Using sequence shown, progressively loosen
and remove 14 bolts securing camshaft cover.
+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.
12-3-22 REPAIRS
ENGINE - K SERIES KV6
$% 12.30.50 $% 12.37.01.99
Remove Remove
1. Disconnect battery earth lead.
2. Tie bonnet back in upright position.
3. Drain cooling system.
+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
4. Remove engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
5. Remove battery carrier.
+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
6. Remove engine ECM.
+ ENGINE MANAGEMENT SYSTEM -
SIEMENS, REPAIRS, Engine control module
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(ECM) - Non NAS.
Refit
1. Fit and secure engine acoustic cover.
2. Connect air intake and air bypass hoses,
secure clip.
3. Connect fresh air intake hose to acoustic cover
and tighten clip screw.
7. Remove 2 screws securing harness clamp and
remove clamp.
8. Disconnect 2 engine harness to main harness
multiplugs.
REPAIRS 12-3-23
ENGINE - K SERIES KV6
9. Release air duct and harness rubber sleeve 13. Remove 2 bolts securing battery and starter
from 'E' box. lead to fuse box.
10. Release 4 clips securing carrier in 'E' box, 14. Disconnect multiplug from fuse box.
remove carrier from 'E' box and position aside.
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M12 6765
M12 6766
12-3-24 REPAIRS
ENGINE - K SERIES KV6
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22. Release clip and disconnect hose from purge
control valve.
CAUTION: Always fit plugs to open
connections to prevent contamination.
REPAIRS 12-3-25
ENGINE - K SERIES KV6
25. Release clips and disconnect heater feed and 28. Release clip and disconnect hose from
return hoses. underside of expansion tank.
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26. Release top hose from support bracket, release 29. Depress locking collar and disconnect brake
clip and disconnect top hose from radiator. servo hose from inlet manifold chamber.
30. Raise vehicle on ramp.
31. Remove front road wheels.
32. Release stake in drive shaft nuts.
12-3-26 REPAIRS
ENGINE - K SERIES KV6
40. Drain gearbox fluid.
+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
41. Drain fluid from IRD.
+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
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FRONT SUSPENSION, REPAIRS,
Rear beam.
35. Remove exhaust front pipe.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - Non
NAS.
+ MANIFOLDS & EXHAUST SYSTEMS M12 6614
- K SERIES KV6, REPAIRS, Front pipe - NAS.
36. Raise one rear wheel for rotation of propeller
42. Remove 6 bolts securing RH and LH front
shaft to access bolts.
splash shields and remove shields.
REPAIRS 12-3-27
ENGINE - K SERIES KV6
48. Using LRT-57-043, separate ball pins from RH 51. Remove nut securing selector lever to selector
and LH steering arms. Remove M12 nuts and shaft on gearbox and release lever from
release ball pins from steering arms. selector shaft.
49. Pull RH and LH hubs outwards and release 52. Release clip securing selector cable to gearbox
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driveshafts from hubs. bracket, remove cable and tie aside.
12-3-28 REPAIRS
ENGINE - K SERIES KV6
M12 6789
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cylinder block. Release A/C compressor and
heat shield and position aside.
56. Lower vehicle on ramp.
M12 6788
REPAIRS 12-3-29
ENGINE - K SERIES KV6
63. Place a wooden block on jack, position jack
under gearbox and raise jack sufficient to
support weight of gearbox. Release lifting hook
from rear engine lifting bracket and connect to
lifting bracket on gearbox.
M12 6605
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69. Remove top arm.
64. Remove bolt securing upper RH engine steady
to top arm.
65. Loosen bolt securing upper RH engine steady
to body, pivot engine steady away from top
arm.
12-3-30 REPAIRS
ENGINE - K SERIES KV6
17. Position A/C compressor to front mounting
plate and cylinder block, align heat shield, fit
and tighten bolts to 25 Nm (18 lbf.ft).
18. Connect multiplug to A/C compressor.
19. Using a 3/8 square drive socket bar, raise
ancillary drive belt tensioner and fit drive belt to
pulleys.
20. Position selector cable to gearbox bracket and
secure with clip.
21. Position selector lever to selector shaft, fit and
tighten nut to 25 Nm (18 lbf.ft).
22. Clean splines and seal areas on each
driveshaft and mating faces in front hubs.
23. Fit new circlips to RH and LH driveshaft inner
joint splines.
24. Fit driveshafts to IRD and gearbox, ensuring
that the circlip on each driveshaft is fully
71. Remove 3 bolts securing PAS pump to front engaged.
mounting plate and tie pump aside. 25. Engage LH and RH driveshafts into front hubs.
72. With assistance, manoeuvre and lower engine 26. Fit new driveshaft flange nuts but do not tighten
and gearbox to floor.
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at this stage.
27. Clean ball joint tapers and taper seats.
Refit 28. Position LH and RH track rod ends to steering
1. With assistance, raise engine and gearbox into arms, fit new nuts and tighten to 55 Nm (40
engine compartment. lbf.ft).
2. Position PAS pump to front mounting plate, fit 29. Clean ABS sensors and mating faces.
and tighten bolts to 25 Nm (18 lbf.ft). 30. Apply anti-seize grease to both ABS sensors
3. Position PAS pump pulley, fit and tighten Torx and position sensors in front hubs.
screws to 9 Nm (7 lbf.ft). Ensure ABS sensor is fully located into hub,
4. Position top arm to engine mounting bracket so that sensor touches pole wheel teeth.
and RH hydramount, fit and tighten bolts to 100
Nm (74 lbf.ft).
31. Position LH and RH brake hoses to front
5. Position PAS pipe support bracket to RH
damper brackets and secure with clips.
hydramount, fit and tighten nut to 85 Nm (63
32. Position LH and RH splash shields, fit and
lbf.ft).
tighten bolts.
6. Place a wooden block on jack, position jack
33. Ensure mating face of propeller shaft and IRD
under gearbox and raise jack sufficient to
drive flange are clean.
support weight of gearbox. Release lifting hook
34. Fit propeller shaft to IRD flange and align
from lifting bracket on gearbox and connect to
marks. Tighten nuts and bolts to 42 Nm (31
rear engine lifting bracket.
lbf.ft).
7. Lower and remove jack supporting gearbox.
35. Fit rear beam.
8. Remove bolts securing LRT-44-026 lifting
bracket to gearbox and remove bracket.
+ FRONT SUSPENSION, REPAIRS,
Rear beam.
9. Position LH mounting bracket to gearbox, fit
36. Fill IRD to correct level with fluid.
and tighten bolts to 85 Nm (63 lbf.ft).
10. Position LH mounting to body, fit and tighten
+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
bolts to 48 Nm.
reduction drive (IRD) fluid - drain & refill -
11. Align gearbox bracket to LH body mounting, fit
Non NAS.
and tighten through bolt to 100 Nm (74 lbf.ft).
12. Position upper RH engine steady to top arm, fit
+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
and tighten bolt to 100 Nm (74 lbf.ft).
reduction drive (IRD) lubrication system -
13. Tighten bolt securing upper RH engine steady
drain & refill - NAS.
to body to 100 Nm (74 lbf.ft).
37. Fit exhaust front pipe.
14. Position PAS pipe to engine front mounting
plate, fit and tighten bolt to 25 Nm (18 lbf.ft).
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - Non
15. Lower hoist, disconnect and remove lifting
NAS.
bracket, LRT-12-138.
16. Raise vehicle on ramp.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - NAS.
REPAIRS 12-3-31
ENGINE - K SERIES KV6
38. With assistant depressing the brake pedal, 67. Fill cooling system.
tighten front hub nuts to 400 Nm (295 lbf.ft). + COOLING SYSTEM - K SERIES KV6,
39. Stake nut to shaft. ADJUSTMENTS, Coolant - drain and refill.
40. Fit front road wheels, fit and tighten nuts to 115 68. Connect battery earth lead.
Nm (85 lbf.ft). 69. Fill gearbox with fluid.
41. Lower vehicle on ramp. + AUTOMATIC GEARBOX - JATCO,
42. Connect brake servo vacuum hose to inlet ADJUSTMENTS, Gearbox fluid - drain &
manifold chamber. refill.
43. Connect coolant hose to underside of 70. Fit engine acoustic cover.
expansion tank and secure with clip. + ENGINE - K SERIES KV6, REPAIRS,
44. Connect expansion tank hose to inlet manifold Cover - engine acoustic.
and secure clip.
45. Connect top hose to radiator and secure with
clip. Position hose in bracket.
46. Connect heater feed and return hoses and
secure with clips.
47. Connect throttle inner cable to throttle cam and
secure outer cable in abutment bracket, if fitted.
48. Secure throttle cable in clips on harness
brackets, if fitted.
49. Adjust throttle cable, if fitted.
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+ FUEL DELIVERY SYSTEM -
PETROL, ADJUSTMENTS, Throttle cable -
check and adjust - KV6.
50. Connect hose to purge control valve.
51. Connect fuel hose to fuel rail pipe, fit rubber
sleeve over hose connector.
52. Connect gearbox harness multiplugs and
secure multiplugs in mounting bracket clips.
53. Connect Lucar connector to starter solenoid.
54. Position earth lead to gearbox housing, fit and
tighten bolt to 25 Nm (18 lbf.ft).
55. Position engine harness to 'E' box mounting
bracket and secure with clips.
56. Connect earth header multiplug.
57. Connect multiplug to underbonnet fuse box.
58. Position battery and starter motor lead to
underbonnet fuse box, fit and tighten bolts to 8
Nm (6 lbf.ft).
59. Fit underbonnet fuse box cover.
60. Position 'E' box, secure in retaining clip, fit and
tighten nut to 9 Nm (7 lbf.ft).
61. Position carrier in 'E' box and secure with clips.
62. Position and secure air duct and harness
rubber sleeve in 'E' box.
63. Connect multiplugs securing main harness to
engine harness.
64. Position ECM harness and multiplug to 'E' box,
align harness clamp and secure screws to 'E'
box.
65. Fit engine ECM.
+ ENGINE MANAGEMENT SYSTEM -
SIEMENS, REPAIRS, Engine control module
(ECM) - Non NAS.
66. Fit battery carrier.
+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
12-3-32 REPAIRS
ENGINE - K SERIES KV6
Refit
Arm assembly - engine mounting RH 1. Position top arm to front engine mounting
bracket, fit and tighten bolts to 100 Nm (74
$% 12.45.06 lbf.ft).
2. Lower and remove jack supporting engine.
Remove 3. Position PAS pipe support bracket to
1. Remove underbelly panel. hydramount.
+ EXTERIOR FITTINGS, REPAIRS, 4. Fit nut securing top arm to RH hydramount and
tighten to 85 Nm (63 lbf.ft).
Panel - underbelly.
2. Remove engine acoustic cover. 5. Position upper RH engine steady to top arm, fit
+ ENGINE - K SERIES KV6, REPAIRS, and tighten bolt to 100 Nm (74 lbf.ft).
6. Tighten bolt securing upper RH engine steady
Cover - engine acoustic.
to body to 100 Nm (74 lbf.ft).
7. Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
8. Fit engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
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3. Remove bolt securing upper RH engine steady
to top arm.
4. Loosen bolt securing upper RH engine steady
to body, pivot engine steady away from top
arm.
5. Fit wooden block to jack, position jack under
engine sump to support engine.
M12 6605
REPAIRS 12-3-33
ENGINE - K SERIES KV6
Refit
Engine mounting - LH 1. Position LH mounting to body, fit and tighten
bolts to 48 Nm (35 lbf.ft).
$% 12.45.11 2. Align gearbox bracket to LH body mounting, fit
and tighten through bolt to 100 Nm (74 lbf.ft).
Remove 3. Lower hoist, disconnect and remove lifting
1. Remove engine acoustic cover. bracket, LRT-12-138.
+ ENGINE - K SERIES KV6, REPAIRS, 4. Fit battery carrier.
+ CHARGING AND STARTING,
Cover - engine acoustic.
2. Remove battery carrier. REPAIRS, Carrier - battery.
+ CHARGING AND STARTING, 5. Fit engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
REPAIRS, Carrier - battery.
Cover - engine acoustic.
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3. Using a hoist, connect adjustable lifting
bracket, LRT-12-138 to engine.
4. Raise hoist to take weight without exerting any
load on the engine mountings.
M12 6599
12-3-34 REPAIRS
ENGINE - K SERIES KV6
$% 12.45.12 $% 12.45.16
Remove Remove
1. Remove top arm.
+ ENGINE - K SERIES KV6, REPAIRS,
Arm assembly - engine mounting RH.
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1. Remove 2 bolts securing RH engine steady to
top arm and body.
2. Remove engine steady from mounting
2. Position 3 pegs on LRT-12-169 into 3 slots in brackets.
hydramount.
3. Connect a suitable socket bar to LRT-12-169, Refit
loosen and remove hydramount and LRT-12- 1. Position engine steady bar, fit bolts and tighten
169. to 100 Nm (74 lbf.ft).
Refit
1. Clean hydramount and body mating faces.
2. Position hydramount to body.
3. Position 3 pegs on LRT-12-169 into 3 slots in
hydramount.
4. Tighten hydramount to 85 Nm (63 lbf.ft).
5. Fit top arm.
+ ENGINE - K SERIES KV6, REPAIRS,
Arm assembly - engine mounting RH.
REPAIRS 12-3-35
ENGINE - K SERIES KV6
$% 12.45.17 $% 12.53.13
Remove Remove
1. Remove underbelly panel. 1. Remove automatic gearbox.
+ EXTERIOR FITTINGS, REPAIRS, + AUTOMATIC GEARBOX - JATCO,
Panel - underbelly. REPAIRS, Gearbox - KV6.
2. Assemble LRT-12-161 to LRT-12-199 and
secure with clamp bolt.
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M12 6597
12-3-36 REPAIRS
ENGINE - K SERIES KV6
Refit
1. Clean bolt holes in crankshaft using an old Filter - engine oil
drive plate bolt with two saw cuts at an angle of
45° to the bolt shank. $% 12.60.04
2. Clean drive plate and mating face of
crankshaft. Remove
3. Position LRT-12-161 and LRT-12-199 to 1. Raise vehicle on a 4 post ramp.
crankshaft pulley to restrain crankshaft. 2. Remove underbelly panel.
4. Position drive plate to crankshaft. + EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3. Place suitable container under oil filter to collect
spillage.
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5. Fit new Patchlok bolts securing drive plate to
crankshaft and tighten in sequence shown to: M12 6660
l Stage 1 - 25 Nm (18 lbf.ft)
l Stage 2 - 100 Nm (74 lbf.ft) 4. Using strap wrench, remove and discard oil
6. Remove LRT-12-161 and LRT-12-199 from filter.
crankshaft pulley. WARNING: Avoid excessive skin contact
7. Fit automatic gearbox. with used engine oil. Used engine oil
+ AUTOMATIC GEARBOX - JATCO, contains potentially harmful contaminants
REPAIRS, Gearbox - KV6. which may cause skin cancer or other
serious skin disorders.
Refit
1. Clean oil filter mating face.
2. Fill canister of replacement oil filter with clean
engine oil.
3. Lubricate new oil filter sealing ring with clean
engine oil.
4. Fit new oil filter and tighten by hand until it
seats, then tighten a further half turn.
5. Remove oil container from underneath of
engine.
6. Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
7. Lower vehicle on ramp.
8. Start and run engine and check for leaks.
9. Stop engine, wait a few minutes, then check oil
level. Top up if necessary.
+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.
REPAIRS 12-3-37
ENGINE - K SERIES KV6
$% 12.60.20 $% 12.60.25
Remove Remove
1. Disconnect battery earth lead. 1. Disconnect battery earth lead.
2. Remove engine sump. 2. Drain engine oil.
+ ENGINE - K SERIES KV6, REPAIRS, + MAINTENANCE, MAINTENANCE,
Sump - reseal. Engine Oil and Filter – KV6.
3. Remove camshaft timing belt.
+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
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3. Remove bolt and remove oil pick-up strainer.
Remove and discard 'O' ring.
12-3-38 REPAIRS
ENGINE - K SERIES KV6
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l Stage 2 - 9 Nm (7 lbf.ft)
REPAIRS 12-3-39
ENGINE - K SERIES KV6
16. Fit camshaft timing belt.
+ ENGINE - K SERIES KV6, REPAIRS, Sump - reseal
Camshaft timing belt.
17. Fill engine with oil. $% 12.60.38
+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6. Remove
18. Connect battery earth lead. 1. Disconnect battery earth lead.
2. Remove engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3. Drain engine oil.
+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.
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M12 6614
M12 7916
12-3-40 REPAIRS
ENGINE - K SERIES KV6
10. Using a mallet, gently tap sump sideways to
break sealant bond, remove sump.
CAUTION: Do not lever between sump and
lower crankcase.
Refit
1. Using a suitable cleaning solvent, clean sump
and mating face on lower crankcase. DO NOT
use a metal scraper on sealing surfaces.
2. Apply a 2 mm (0.1 in) bead of sealant, Part No.
STC 4600 along centre of sump flange, then
spread to an even film using a roller.
CAUTION: To avoid contamination,
M12 6672 assembly must be completed immediately
after application of sealant.
6. Remove bolt securing dipstick tube to cylinder
block.
7. Depress and hold down dipstick collar, remove
dipstick tube from sump.
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5 1 3
8 10
7 9
6 2 4
M12 6675
REPAIRS 12-3-41
ENGINE - K SERIES KV6
Refit
Switch - oil pressure 1. Ensure oil pressure switch and mating face is
clean.
$% 12.60.50 2. Fit oil pressure switch using a new sealing
washer and tighten to 14 Nm (10 lbf.ft).
Remove 3. Connect multiplug to oil pressure switch.
1. Disconnect battery earth lead. 4. Remove oil container from underneath of
2. Remove underbelly panel. engine.
+ EXTERIOR FITTINGS, REPAIRS, 5. Fit splash shield and secure with bolts.
6. Fit RH road wheel and tighten nuts to 115 Nm
Panel - underbelly.
3. Remove RH front road wheel. (85 lbf.ft).
7. Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
8. Check engine oil level, top-up if necessary.
9. Connect battery earth lead.
cardiagn.com
M12 6614
12-3-42 REPAIRS
ENGINE - K SERIES KV6
$% 12.60.56
Remove
1. Disconnect battery earth lead.
2. Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3. Remove RH front road wheel.
M12 7916
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M12 6614
Refit
1. Clean valve, spring and plug.
2. Clean valve seating inside oil pump housing.
3. Check that valve slides freely in bore and that
valve and bore are free from scoring and
M12 6660 corrosion.
Note: Light corrosion may be removed using
6. Using strap wrench, remove and discard oil grade 600 emery cloth soaked in oil.
filter.
4. Check free length of spring.
+ GENERAL DATA, Engine – KV6
Petrol.
5. Apply Loctite 577 sealant to plug thread.
Note: If a hexagonal head plug and sealing
washer were fitted, fit new sealing washer to
plug.
REPAIRS 12-3-43
ENGINE - K SERIES KV6
6. Fit valve, spring and plug to oil pump housing.
Tighten plug to 25 Nm (18 lbf.ft). Oil cooler - engine
7. Fill canister of replacement oil filter with clean
engine oil. $% 12.60.68
8. Lubricate new oil filter seal with clean engine oil
and fit filter. Remove
9. Position engine oil cooler to mounting bracket, 1. Disconnect battery earth lead.
fit and tighten nuts to 25 Nm (18 lbf.ft). 2. Drain cooling system.
10. Remove oil container from underneath of
engine.
+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
11. Fit splash shield and secure with bolts. 3. Remove RH front road wheel.
12. Fit RH road wheel and tighten nuts to 115 Nm
(85 lbf.ft).
13. Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
14. Connect battery earth lead.
15. Check engine oil level, top-up if necessary.
cardiagn.com
M12 6614
M12 7917
12-3-44 REPAIRS
ENGINE - K SERIES KV6
9. Remove 4 nuts securing engine oil cooler to
mounting bracket and remove oil cooler. Camshaft timing belt
10. Restrain oil cooler pipe bosses on oil cooler
housing, loosen and remove oil cooler pipes $% 12.65.18
from oil cooler; remove and discard 2 'O' rings.
CAUTION: Always fit plugs to open Remove
connections to prevent contamination. 1. Disconnect battery earth lead.
2. Remove ancillary drive belt.
Refit + CHARGING AND STARTING,
1. Clean oil cooler pipe unions and mating faces. REPAIRS, Ancillary drive belt - KV6.
2. Lubricate new 'O' rings with clean engine oil 3. Remove RH front road wheel.
and fit to oil cooler pipes.
3. Fit pipes to engine oil cooler, restrain bosses on
oil cooler body and tighten unions to 26 Nm (19
lbf.ft).
CAUTION: To prevent damage to
components, use two spanners when
loosening or tightening unions.
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fit and tighten nuts to 25 Nm (18 lbf.ft).
5. Position oil cooler pipes to oil filter housing and
tighten unions to 26 Nm.
6. Connect coolant hoses to oil cooler and secure
with clips. M12 6614
7. Fit splash shield and secure with bolts.
8. Fit RH road wheel and tighten nuts to 115 Nm
4. Remove 3 bolts securing RH splash shield to
(85 lbf.ft).
body and remove shield.
9. Fill cooling system.
+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
10. Connect battery earth lead.
11. Check engine oil level and top-up if necessary.
+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.
REPAIRS 12-3-45
ENGINE - K SERIES KV6
LRT-12-232
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9. Using a socket on crankshaft pulley bolt, rotate
crankshaft in a clockwise direction. Align the
engine "SAFE" position, notch on crankshaft
11. Remove bolt securing PAS pipe to engine front
pulley with the "ARROW" on front mounting
mounting plate.
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.
12-3-46 REPAIRS
ENGINE - K SERIES KV6
16. Remove lower bolt and upper nut and bolt
securing alternator to front mounting plate.
17. Remove alternator.
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front mounting plate and remove pulley.
REPAIRS 12-3-47
ENGINE - K SERIES KV6
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25. Remove tools LRT-12-161 and LRT-12-199
from crankshaft pulley, remove pulley.
12-3-48 REPAIRS
ENGINE - K SERIES KV6
M12 6672
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M12 6626
REPAIRS 12-3-49
ENGINE - K SERIES KV6
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NOTE: If holes in body and plunger are not
aligned, move tensioner backplate using a
suitable broad bladed screwdriver; this will
move plunger sufficiently to enable pin to be
inserted.
12-3-50 REPAIRS
ENGINE - K SERIES KV6
40. With care, ease camshaft timing belt from
gears using fingers only and remove timing
belt.
CAUTION: Do not rotate crankshaft or
camshafts with timing belt removed and
cylinder heads fitted.
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seizure has occurred. Do not use a otherwise damage to camshafts may occur.
camshaft timing belt if mileage exceeds
72,000 km (45,000 miles). Do not use an oil
or coolant contaminated timing belt, cause 43. Remove and discard bolts retaining front inlet
of contamination must be rectified. camshaft gears to camshafts.
44. Remove tools LRT-12-196 from both inlet
camshaft gears and exhaust camshafts.
45. Remove camshaft drive gears and hub
assemblies.
Refit
NOTE: Following front or rear timing belt
refitment, it is possible that, after rotating the
engine and positioning the crankshaft pulley to
the 'SAFE' position, the timing marks on the
rear timing gears may be misaligned. This
misalignment is acceptable provided that the
timing belt refitting procedure was carried out
correctly.
REPAIRS 12-3-51
ENGINE - K SERIES KV6
3. Position timing belt to crankshaft gear. 9. Using fingers only, fit timing belt to gears,
NOTE: To prevent the timing belt from starting at the crankshaft gear and working in
disengaging from the crankshaft gear when an anti-clockwise direction, keeping the belt run
fitting, fit a suitable wedge between the belt and as taut as possible and turning the camshaft
oil pump belt guard. gears only a minimum amount anti-clockwise to
fit timing belt.
CAUTION: Gears must not be rotated anti-
clockwise more than one tooth.
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4. Fit tool LRT-12-197 into each exhaust
camshaft in turn.
12-3-52 REPAIRS
ENGINE - K SERIES KV6
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otherwise damage to camshafts may occur. l Bolt No. 5 - 45 Nm (33 lbf.ft)
l Bolts Nos. 2, 3, 4, 6 and 7 - 85 Nm (63 lbf.ft)
24. Position engine lifting bracket, fit bolts securing
14. Tighten front inlet camshaft gear bolts to:
lifting bracket and front mounting plate to
l Stage 1 - 27 Nm (20 lbf.ft)
cylinder block and RH cylinder head. Tighten
l Stage 2 - Further 90°
M10 bolts to 45 Nm (33 lbf.ft) and M8 bolt to 25
15. Remove tools LRT-12-196 from both inlet
Nm (18 lbf.ft).
camshaft gears and exhaust camshafts.
25. Clean end of dipstick tube.
16. Remove wedge from between drive belt and oil
26. Position dipstick tube to sump and cylinder
pump belt guard.
block, fit bolt and tighten to 9 Nm (7 lbf.ft).
17. Remove 1.5 mm diameter pin from tensioner.
27. Position A/C compressor to front mounting
18. Fit rubber blanking plug around tensioner.
plate and cylinder block, align heat shield, fit
19. Remove timing pin LRT-12-232.
and tighten bolts to 25 Nm (18 lbf.ft).
20. Clean exhaust camshaft front cap seal
28. Clean lower timing belt cover.
locations and fit new cap seals.
29. Position lower timing belt cover, fit and tighten
CAUTION: The sealing edge of the cap seal bolts to 9 Nm (7 lbf.ft).
and mating face must be clean and dry. 30. Clean crankshaft pulley.
31. Fit crankshaft pulley to crankshaft gear and
21. Position engine front mounting plate and ensure that the indent on pulley locates over
manoeuvre plate into position. Fit bolts but do the lug on crankshaft gear.
not tighten at this stage. 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-
199from crankshaft pulley.
34. Clean ancillary drive belt tensioner.
35. Position ancillary belt tensioner, fit bolts and
tighten to 25 Nm (18 lbf.ft).
36. Clean LH and RH front timing belt covers.
37. Position LH and RH front timing belt covers, fit
and tighten bolts to 4 Nm (3 lbf.ft).
38. Clean idler pulley, position pulley to engine
front mounting plate and tighten Allen bolt to 45
Nm (33 lbf.ft).
39. Position alternator to front mounting plate.
REPAIRS 12-3-53
ENGINE - K SERIES KV6
40. Fit bolt and nut and bolt securing alternator to
front mounting plate and tighten to 45 Nm (33 Camshaft timing belt cover - RH front
lbf.ft).
41. Connect alternator multiplug. $% 12.65.39
42. Connect battery lead to alternator, fit and
tighten nut to 8 Nm (6 lbf.ft), fit terminal cover. Remove
43. Position PAS pump to front mounting plate, fit 1. Disconnect battery earth lead.
and tighten bolts to 25 Nm (18 lbf.ft). 2. Remove ancillary drive belt.
44. Position PAS pipe to engine front mounting
plate, fit and tighten bolt to 25 Nm (18 lbf.ft).
+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - KV6.
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
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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 3. Remove 3 bolts securing camshaft timing belt
- K SERIES KV6, REPAIRS, Seals - inlet RH front cover and remove cover.
manifold chamber.
55. Fit RH road wheel and tighten nuts to 115 Nm Refit
(85 lbf.ft). 1. Clean RH front timing belt cover.
56. Fit ancillary drive belt. 2. Position RH front timing belt cover, fit and
+ CHARGING AND STARTING, tighten bolts to 4 Nm (3 lbf.ft).
REPAIRS, Ancillary drive belt - KV6. 3. Fit ancillary drive belt.
+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - KV6.
4. Connect battery earth lead.
12-3-54 REPAIRS
ENGINE - K SERIES KV6
$% 12.65.41
Remove
1. Disconnect battery earth lead.
2. Remove ancillary drive belt.
+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - KV6.
M12 6672
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3. Remove 3 Torx screws securing PAS pump
pulley, and remove pulley.
Refit
1. Clean LH front timing belt cover.
2. Position LH front timing belt cover, fit and
tighten bolts to 4 Nm (3 lbf.ft).
3. Position dipstick tube bracket to cylinder block
and tighten bolt to 9 Nm (7 lbf.ft).
4. Clean idler pulley, position pulley to engine
front mounting plate and tighten Torx bolt to 45
4. Remove Torx screw securing idler pulley to Nm (33 lbf.ft).
front mounting plate and remove pulley. 5. Position PAS pump pulley, fit and tighten Torx
screws to 9 Nm (7 lbf.ft).
6. Fit ancillary drive belt
+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - KV6.
7. Connect battery earth lead.
REPAIRS 12-3-55
ENGINE - K SERIES KV6
Camshaft timing belt cover - LH rear Camshaft timing belt cover - RH rear
$% 12.65.46 $% 12.65.47
Remove Remove
1. Disconnect battery earth lead. 1. Disconnect battery earth lead.
2. Remove engine acoustic cover. 2. Remove inlet manifold chamber.
+ ENGINE - K SERIES KV6, REPAIRS, + MANIFOLDS & EXHAUST SYSTEMS
Cover - engine acoustic. - K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber.
cardiagn.com
M12 6694
12-3-56 REPAIRS
ENGINE - K SERIES KV6
$% 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.
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
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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.
M12 6614
LRT-12-232
M12 7927
REPAIRS 12-3-57
ENGINE - K SERIES KV6
12. Remove LRT-12-175 from camshaft gears and
remove timing belt from gears.
CAUTION: Do not rotate crankshaft or
camshafts with timing belt removed and
cylinder heads fitted.
cardiagn.com
of contamination must be rectified.
Refit
NOTE: Following front or rear timing belt
refitment, it is possible that after rotating the
engine and positioning the crankshaft pulley to
the 'SAFE' position, the timing marks on the
rear timing gears may be misaligned. This
misalignment is acceptable provided that the
timing belt refitting procedure was carried out
correctly.
12-3-58 REPAIRS
ENGINE - K SERIES KV6
2. Place gears inverted on a flat surface, with the 7. Fit LRT-12-198 alignment pins into the end of
locating lugs on the gears positioned as each camshaft.
illustrated. 8. Position timing belt and gears over LRT-12-198
and locate gears onto camshafts.
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3. Keeping the timing marks aligned, position
timing belt onto gears. 9. Position LRT-12-197 into the front end of the
4. Position LRT-12-195 between the gears, turn LH exhaust camshaft.
centre nut sufficiently to spread drive belt. 10. With assistance, using a 30 mm socket on LRT-
5. Invert gears and timing belt and position LRT- 12-197, turn the LH exhaust camshaft
12-175 to camshaft gears. sufficiently to align camshaft gears to the drive
6. Check that the locating lugs are still aligned and slots in each camshaft.
remove LRT-12-195 from between camshaft
gears.
REPAIRS 12-3-59
ENGINE - K SERIES KV6
$% 12.65.57
Remove
1. Disconnect battery earth lead.
2. Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3. Remove RH front road wheel.
cardiagn.com
l Stage 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 M12 6614
crankcase.
17. Fit splash shield and secure with bolts. 4. Remove 3 bolts securing RH splash shield to
18. Fit RH road wheel and tighten nuts to 115 Nm body and remove shield.
(85 lbf.ft). 5. Remove RH rear timing belt cover.
19. Fit LH rear timing belt cover. + ENGINE - K SERIES KV6, REPAIRS,
+ ENGINE - K SERIES KV6, REPAIRS, Camshaft timing belt cover - RH rear.
Camshaft timing belt cover - LH rear.
20. Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
21. Connect battery earth lead.
12-3-60 REPAIRS
ENGINE - K SERIES KV6
cardiagn.com
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.
REPAIRS 12-3-61
ENGINE - K SERIES KV6
12. Remove LRT-12-175 from camshaft gears and
remove timing belt from gears.
CAUTION: Camshaft timing belts must be
stored and handled with care. Always store
a camshaft timing belt on its edge with a
bend radius greater than 50 mm (2.0 in). Do
not use a camshaft timing belt that has been
twisted or bent double as this will damage
the reinforcing fibres. Do not use a
camshaft timing belt if debris other than belt
dust is found in timing belt covers. Do not
use a camshaft timing belt if partial engine
seizure has occurred. Do not use a
camshaft timing belt if mileage exceeds
72,000 km (45,000 miles). Do not use an oil
or coolant contaminated timing belt, cause
of contamination must be rectified. 2. Place gears inverted on a flat surface, with the
locating lugs on the gears positioned as
Refit illustrated.
NOTE: Following front or rear timing belt
cardiagn.com
refitment, it is possible that after rotating the
engine and positioning the crankshaft pulley to
the 'SAFE' position, the timing marks on the
rear timing gears may be misaligned. This
misalignment is acceptable provided that the
timing belt refitting procedure was carried out
correctly.
12-3-62 REPAIRS
ENGINE - K SERIES KV6
6. Check that the locating lugs are correctly
aligned and remove LRT-12-195 from between
camshaft gears.
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each camshaft. l Stage 2 - Further 90°
8. Position timing belt and gears over LRT-12-198 13. Remove LRT-12-175 from camshaft gears.
and locate gears onto camshafts. 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.
REPAIRS 12-3-63
ENGINE - K SERIES KV6
cardiagn.com
12-3-64 REPAIRS
ENGINE - K SERIES KV6
OVERHAUL
$% 12.17.03.01
Disassembly
1. Remove crankshaft.
+
ENGINE - K SERIES KV6,
OVERHAUL, Crankshaft.
cardiagn.com
8. Using a suitable expander, remove and discard
piston rings from each piston.
9. Using a squared off end of an old piston ring,
remove carbon from piston ring grooves.
OVERHAUL 12-3-65
ENGINE - K SERIES KV6
M12 6838
cardiagn.com
and colour code are marked on the external
diameter of the cylinder liners. If cylinder(s) are
7. Piston rings - refit:Using a suitable expander,
to be replaced, the replacement liner(s) must
fit oil control spring.
have the same step height as the original
8. With 'TOP' or identification markings to top of
liner(s). Both step heights are available in red
piston, use an expander to fit piston rings in
(A) and blue (B) grades of cylinder liners.
+ GENERAL DATA, Engine – KV6
sequence; oil control, 2nd and top
compression.
Petrol.
3. Check pistons for distortion and cracks. NOTE: The second compression ring is
stepped.
NOTE: Piston grades A or B are stamped on
the crown of the piston.
12-3-66 OVERHAUL
ENGINE - K SERIES KV6
7. Keeping cylinder liner 'square' to cylinder block,
push each liner fully down until shoulder of liner
seats against cylinder block ensuring that the
arrow on the piston is towards front of engine.
8. To prevent cylinder liners from being displaced,
position LRT-12-144 cylinder liner clamps and
secure to cylinder block with cylinder head
bolts. Ensure that feet of clamps do not
protrude over liner bores.
9. Fit crankshaft.
+ ENGINE - K SERIES KV6,
OVERHAUL, Crankshaft.
cardiagn.com
Reassembly
1. Clean cylinder liners and liner recess in cylinder
block.
2. Lubricate cylinder liner bores, pistons and rings
with clean engine oil, ensure ring gaps are
correctly spaced.
3. Clean bearing shell recesses in connecting
rods and bearing caps.
4. Fit piston ring clamp, LRT-12-204 to each
piston in turn and fit piston to its respective
cylinder liner ensuring that when fitted, arrow
on piston crown will be towards front of engine.
CAUTION: Do not push pistons fully down
bores at this stage.
M12 6842
OVERHAUL 12-3-67
ENGINE - K SERIES KV6
$% 12.21.14.01
Remove
1. Remove camshaft timing belt.
+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.
cardiagn.com
4. Remove LRT-12-202 and oil seal guide from
crankshaft.
5. Clean crankshaft gear and wipe end of
crankshaft.
6. Fit drive gear to crankshaft.
2. Remove crankshaft drive gear. 7. Fit camshaft timing belt.
+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.
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.
12-3-68 OVERHAUL
ENGINE - K SERIES KV6
$% 12.21.20.01
Remove
1. Remove automatic gearbox.
+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gearbox - KV6 - with engine and
gearbox removed.
2. Assemble LRT-12-161 to LRT-12-199 and
secure with clamp bolt.
cardiagn.com
Refit
1. Clean cylinder block face and oil seal running
surface on crankshaft, ensure bolt holes are
clean and dry.
OVERHAUL 12-3-69
ENGINE - K SERIES KV6
Crankshaft
$% 12.21.33.01
Remove
1. Remove cylinder head gaskets.
+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - LH.
+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - RH.
2. Remove oil pump gasket.
+ ENGINE - K SERIES KV6,
OVERHAUL, Oil pump.
3. Remove crankshaft rear oil seal.
+ ENGINE - K SERIES KV6,
4. Fit new Patchlok bolts securing oil seal to OVERHAUL, Crankshaft rear oil seal.
cylinder block and using sequence shown, 4. Remove engine sump.
tighten to 8 Nm (6 lbf.ft). + ENGINE - K SERIES KV6,
5. Remove oil seal protector LRT-12-061. OVERHAUL, Sump - engine oil.
cardiagn.com
6. Clean bolt holes in crankshaft using an old
drive plate bolt with two saw cuts at an angle of Disassembly
45° to the bolt shank.
7. Clean drive plate and mating face of
crankshaft.
8. Position drive plate to crankshaft and fit but do
not tighten new Patchlok bolts.
9. Position LRT-12-161 and LRT-12-199 to
crankshaft pulley to restrain crankshaft.
12-3-70 OVERHAUL
ENGINE - K SERIES KV6
M12 6858
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securing lower crankcase to cylinder block.
4. Remove lower crankcase.
M12 6835
OVERHAUL 12-3-71
ENGINE - K SERIES KV6
13. Remove crankshaft, remove main bearing Inspect
shells and thrust washers from cylinder block. 1. Check crankshaft main journal diameters.
Discard thrust washers. 2. Diameters should be within tolerances.
Replace crankshaft if outside tolerance.
+ GENERAL DATA, Engine – KV6
Petrol.
3. Determine appropriate main bearing shells to
be fitted from size selection and type tables in
general data.
+ GENERAL DATA, Engine – KV6
Petrol.
4. Determine main bearing thickness by colour
code on edge of bearing.
+ GENERAL DATA, Engine – KV6
Petrol.
5. Crankshaft big-end journal
diameters:Check crankshaft big-end journal
diameters; replace crankshaft if outside
tolerance.
14. Main bearings - selection: record main
+ GENERAL DATA, Engine – KV6
Petrol.
cardiagn.com
bearing code letters from front face of cylinder
6. Determine big-end bearing thickness by colour
block. Reading from left to right, the first letter
code on edge of bearing.
relates to No.1, (front) main bearing journal.
+ GENERAL DATA, Engine – KV6
Petrol.
12-3-72 OVERHAUL
ENGINE - K SERIES KV6
cardiagn.com
required bearing shells from general data. Petrol.
+ GENERAL DATA, Engine – KV6 CAUTION: If end-float exceeds limits given,
Petrol. crankshaft must be replaced.
10. Ensure all bolt holes are clean and dry.
Remove all traces of thread locking material
Reassembly
from oil pick-up strainer bolt hole.
1. Fit selected big-end bearing shells to
CAUTION: Do not use a tap. connecting rods and caps.
2. Lubricate crankshaft journals with clean engine
11. Ensure bearing ladder locating dowels are oil. Hold crankshaft with big end journals
fitted and dowel holes in bearing ladder are horizontal, lower crankshaft into main bearings.
clean and dry. 3. Carefully pull connecting rods into place, fit
12. Check coolant stub pipe in cylinder block for connecting rod caps noting that featherways
signs of leakage and corrosion, replace as are on opposite sides; fit and lightly tighten
necessary. Seal replacement pipe with Loctite dowel bolts.
638. 4. Tighten dowel bolts to:
13. Clean main bearing shell recesses in cylinder l Stage 1 - 20 Nm (15 lbf.ft)
block. l Stage 2 - Further 45°
14. Clean crankshaft main bearing and big end 5. Using a lint free cloth and a suitable cleaning
bearing journals. Clean bearing shell locations solvent, clean bearing ladder and mating face
in connecting rods and caps. on cylinder block.
15. Fit selected main bearing shells, grooved into 6. Apply clean engine oil to crankshaft thrust
cylinder block and plain into bearing ladder. washers and fit to bearing ladder with oil
16. Fit new thrust washers to cylinder block. grooves facing outwards.
7. Fit bearing ladder and ensure that all bearing
shells are seated correctly.
OVERHAUL 12-3-73
ENGINE - K SERIES KV6
cardiagn.com
9. Using a lint free cloth and a suitable cleaning
solvent, clean mating surfaces on cylinder
block and lower crankcase.
12-3-74 OVERHAUL
ENGINE - K SERIES KV6
Refit
1. Fit oil pump gasket. Cylinder head gasket - LH
+ ENGINE - K SERIES KV6,
OVERHAUL, Oil pump. $% 12.29.02.01
2. Fit engine sump.
+ ENGINE - K SERIES KV6, Remove
OVERHAUL, Sump - engine oil. 1. Remove and discard camshaft timing belt.
3. Fit crankshaft rear oil seal.
+ ENGINE - K SERIES KV6,
+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.
OVERHAUL, Crankshaft rear oil seal. 2. Remove inlet manifold chamber.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, OVERHAUL, Gasket(s) -
manifold chamber.
LRT-12-232
cardiagn.com
M12 7927
OVERHAUL 12-3-75
ENGINE - K SERIES KV6
7. Release clip and disconnect coolant bleed 10. Remove 2 bolts securing protection cover - if
hose from LH inlet manifold, position hose fitted and RH fuel rail to RH inlet manifold,
aside. remove cover.
cardiagn.com
8. Depress locking collar and release breather 11. Remove 2 bolts securing fuel rail to LH inlet
hose from LH inlet manifold. manifold.
12. Release injectors from manifolds and carefully
lay fuel rail and injectors aside.
CAUTION: Always fit plugs to open
connections to prevent contamination.
12-3-76 OVERHAUL
ENGINE - K SERIES KV6
Refit
1. Clean cylinder head face.
CAUTION: Use suitable gasket removal
spray and a plastic scraper.
cardiagn.com
head on blocks of wood. 2. Remove bolts securing cylinder liner clamps
LRT-12-144 to cylinder block and remove
15. Remove and discard cylinder head gasket. clamps.
CAUTION: Do not rotate crankshaft with RH CAUTION: Do not rotate crankshaft.
cylinder head fitted.
3. Clean cylinder block face and dowel holes.
16. Remove and discard 2 cylinder head locating 4. Clean cylinder head bolts and wipe dry.
dowels. 5. Lightly lubricate threads and beneath heads of
NOTE: Replacement dowels are supplied with cylinder head bolts with clean engine oil.
new cylinder head gasket. 6. Fit 2 new locating dowels supplied with
replacement cylinder head gasket.
OVERHAUL 12-3-77
ENGINE - K SERIES KV6
cardiagn.com
l Stage 4 - Using an angle torque gauge, 28. Connect HO2S multiplug and secure to support
tighten a bolts in same sequence a further bracket.
180° 29. Fit new camshaft timing belt.
12. Fit LH camshaft cover gasket. + ENGINE - K SERIES KV6,
+ ENGINE - K SERIES KV6, REPAIRS, OVERHAUL, Camshaft timing belt.
Camshaft cover gasket - LH.
13. Remove and discard 'O' rings from injectors.
14. Clean injectors and injector locations in fuel rail.
15. Lubricate new 'O' rings with castor oil and fit to
injectors.
16. Position fuel rail assembly and secure injectors
to inlet manifolds.
17. Position injector protection cover - if fitted to RH
fuel rail and secure injector harness to
protection cover or fuel rail with clips.
18. Fit bolts securing fuel rail to inlet manifolds and
tighten to 9 Nm (7 lbf.ft).
19. Connect coolant bleed hose to inlet manifold
and secure with clip.
20. Connect breather hose to LH inlet manifold.
21. Position ignition coils to LH inlet manifold.
22. Position earth lead, fit nuts and bolts securing
ignition coils to LH inlet manifold and tighten to
9 Nm (7 lbf.ft).
23. Clean camshaft drive belt cover backplate bolts
and apply Loctite 242 to first 3 threads.
24. Position backplate, fit and tighten bolts to 9 Nm
(7 lbf.ft).
25. Clean exhaust manifold and cylinder head
mating face.
12-3-78 OVERHAUL
ENGINE - K SERIES KV6
$% 12.29.03.01
Remove
1. Remove inlet manifold chamber.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, OVERHAUL, Gasket(s) -
manifold chamber.
2. Remove and discard camshaft timing belt.
+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.
cardiagn.com
ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - RH.
M30 0996
OVERHAUL 12-3-79
ENGINE - K SERIES KV6
10. Release clip and disconnect coolant bleed 13. Remove 2 bolts securing fuel rail to LH inlet
hose from RH inlet manifold, position hose manifold.
aside. 14. Release injectors from manifolds and carefully
lay fuel rail and injectors aside.
cardiagn.com
CAUTION: Always fit plugs to open
connections to prevent contamination.
12-3-80 OVERHAUL
ENGINE - K SERIES KV6
cardiagn.com
block with the word 'TOP' uppermost.
Refit
9. With assistance, fit cylinder head and carefully
1. Clean cylinder head face.
position RH inlet to LH inlet manifold.
CAUTION: Use suitable gasket removal 10. Carefully enter cylinder head bolts, DO NOT
spray and a plastic scraper. DROP. Screw bolts into place by hand.
OVERHAUL 12-3-81
ENGINE - K SERIES KV6
17. Position injector protection cover - if fitted to RH
fuel rail and secure injector harness to Cylinder head - decarbonise
protection cover or fuel rail with clips.
18. Fit bolts securing fuel rail to inlet manifolds and $% 12.29.19
tighten to 9 Nm (7 lbf.ft).
19. Connect coolant bleed hose to inlet manifold Remove
and secure with clip. 1. Remove cylinder head gaskets.
20. Position ignition coils to LH inlet manifold.
21. Position earth lead, fit nuts and bolts securing
+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - LH.
ignition coils to LH inlet manifold and tighten to
9 Nm (7 lbf.ft).
+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - RH.
22. Connect multiplugs to plug top coils and secure
with locking clips. Disassembly
23. Clean camshaft timing belt cover backplate
bolts and apply Loctite 242 to the first 3 threads.
24. Position backplate, fit and tighten bolts to 9 Nm
(7 lbf.ft).
25. Fit new camshaft timing belt.
+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.
26. Clean exhaust manifold and mating face on
cardiagn.com
cylinder head.
M12 6880
M12 6694
12-3-82 OVERHAUL
ENGINE - K SERIES KV6
4. Position LRT-12-175 to rear camshaft gears as 9. Progressively loosen then remove 7 bolts
illustrated, remove and discard bolts securing securing inlet manifold to cylinder head,
gears to camshafts. remove inlet manifold and discard gasket.
5. Remove rear camshaft gears, timing belt and
cardiagn.com
LRT-12-175 as an assembly.
6. Remove LRT-12-175 from camshaft gears and
remove timing belt from gears. Discard timing
belt.
7. Remove spark plugs.
M12 6882
M12 6883
OVERHAUL 12-3-83
ENGINE - K SERIES KV6
12. Check end-float of camshafts using a DTI. 15. Remove camshafts and discard oil seals.
+ GENERAL DATA, Engine – KV6 Note: Inlet camshafts are colour coded orange,
Petrol. exhaust camshafts
CAUTION: If camshaft end-float exceeds
limits given, repeat check with new
cardiagn.com
16. Using a stick magnet, remove 12 hydraulic
camshaft(s). If end-float is still excessive, tappets from cylinder head.
replace cylinder head and camshaft carrier
CAUTION: Store hydraulic tappets in their
as an assembly.
fitted order and store upright. Maintain
absolute cleanliness when handling
hydraulic tappets. Failure to observe these
precautions can result in engine failure.
12-3-84 OVERHAUL
ENGINE - K SERIES KV6
LRT-12-071
M12 6889
cardiagn.com
Inspect
1. Clean camshafts, bearing running surfaces in
carrier and cylinder head, carrier and cylinder
head mating faces.
2. Inspect camshafts and replace camshafts if
scored, pitted or excessively worn.
3. Position camshafts in cylinder head and place
.051
.025
mm
.038
.076
Plastigauge across each journal.
CAUTION: Ensure camshafts are in their
correct fitted locations. Camshafts are
colour coded - Inlet - Orange; Exhaust -
Blue.
M12 6887
OVERHAUL 12-3-85
ENGINE - K SERIES KV6
13. Check cylinder head face for warping, across 16. Remove carbon deposits from exhaust valve
centre and from corner to corner. guides using a 6 mm diameter reamer inserted
+ GENERAL DATA, Engine – KV6 from combustion side of cylinder head.
Petrol. 17. Remove carbon from inlet valve guides, inlet
cardiagn.com
and exhaust valves and valve seat inserts.
Remove all loose carbon on completion.
12-3-86 OVERHAUL
ENGINE - K SERIES KV6
cardiagn.com
zero gauge ensuring that stylus of gauge
remains in contact with valve head.
23. Move valve towards rear of cylinder head,
record gauge reading obtained to give valve
stem to guide clearance 'B'.
+ GENERAL DATA, Engine – KV6
Petrol.
24. Remove valves ensuring they are retained in LRT-12-519-1
their fitted order.
25. Renew valves and/or guides as necessary.
LRT-12-519-3
26. To replace valve guides support cylinder head
face down on wooden blocks. LRT-12-519-2
M12 6892
OVERHAUL 12-3-87
ENGINE - K SERIES KV6
38. Apply Prussian Blue to valve seat, insert valve
and press it into position several times without
rotating. Remove and check valve for even and
central seating: seating position shown by
A
Prussian Blue should be in the centre of valve
face: a: High towards stem, increase 60° cut
and restore seat width. b: Low towards edge,
increase 45° cut and restore seat width. Lap
and recheck valve seating.
M12 7894
cardiagn.com
when removing insert.
12-3-88 OVERHAUL
ENGINE - K SERIES KV6
4. Fit spring and spring cap.
cardiagn.com
7. Release valve spring and remove tool LRT-12- assembly should be completed immediately
034. after application of sealant.
8. Using a wooden dowel and mallet, lightly tap
top of each valve two or three times to seat
valves and collets.
9. Thoroughly clean and lubricate hydraulic
tappets with clean engine oil. Fit hydraulic
tappets to original bores in cylinder head.
10. Ensure that mating faces of camshaft carrier
and cylinder head are clean and dry.
11. Lubricate camshafts and bearing journals with
clean engine oil.
OVERHAUL 12-3-89
ENGINE - K SERIES KV6
cardiagn.com
not use tool LRT-12-148 for fitting seals.
12-3-90 OVERHAUL
ENGINE - K SERIES KV6
25. Fit LRT-12-198 alignment pins into the end of 29. Remove LRT-12-198 alignment pins and fit
each camshaft. new camshaft gear retaining bolts.
26. Position timing belt and gears over LRT-12-198 30. Tighten camshaft gear bolts to:
and locate gears onto camshafts. l Stage 1 - 27 Nm (20 lbf.ft)
cardiagn.com
l Stage 2 - Further 90°
31. Remove LRT-12-175 from camshaft gears.
32. Remove LRT-12-197 from front end of exhaust
camshaft.
NOTE: Following front or rear timing belt
refitment, it is possible that after rotating the
engine and positioning the crankshaft pulley to
the 'SAFE' position, the timing marks on the
rear timing gears may be misaligned. This
misalignment is acceptable provided that the
timing belt refitting procedure was carried out
correctly.
OVERHAUL 12-3-91
ENGINE - K SERIES KV6
Oil pump
$% 12.60.26.02
Remove
1. Remove camshaft timing belt.
+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.
cardiagn.com
Disassembly
12-3-92 OVERHAUL
ENGINE - K SERIES KV6
Inspect
cardiagn.com
body taking care to ensure that rotors are
retained in pump body.
Note: Cover plate is dowel located.
OVERHAUL 12-3-93
ENGINE - K SERIES KV6
4. Remove spring and valve.
5. Check that valve and bore are free from scoring
and corrosion.
Note: Light corrosion may be removed using
grade 600 emery cloth soaked in engine oil.
Reassembly
1. Clean cover plate and mating face of cylinder 4. Fit new Patchlok bolts and using sequence
block; ensure bolt holes are clean and dry. shown, tighten to :
2. Clean running surface on crankshaft. l Stage 1 - 5 Nm (4 lbf.ft)
3. Remove all traces of Loctite from relief valve l Stage 2 - 9 Nm (7 lbf.ft)
plug, Torx screws and tapped holes in pump
cardiagn.com
body.
CAUTION: Do not use a tap.
12-3-94 OVERHAUL
ENGINE - K SERIES KV6
$% 12.60.38.01
Remove
1. Drain engine oil.
+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.
cardiagn.com
break sealant bond, remove sump.
CAUTION: Do not lever between crankcase
M12 7916
and sump.
5 1 3
M12 6672
8 10
3. Remove bolt securing dipstick tube to cylinder
block.
4. Depress and hold down dipstick tube collar; 7 9
remove dipstick tube from sump.
6 2 4
M12 6675
OVERHAUL 12-3-95
ENGINE - K SERIES KV6
5. Position dipstick tube to sump and cylinder
block, fit bolt and tighten to 9 Nm (7 lbf.ft). Camshaft timing belt
6. Fill engine with oil.
+ CAPACITIES, FLUIDS AND $% 12.65.18.01
LUBRICANTS, Lubrication.
Remove
cardiagn.com
M86 5264
12-3-96 OVERHAUL
ENGINE - K SERIES KV6
4. Remove Torx screw securing idler pulley to 9. Remove 3 bolts securing camshaft timing belt
front mounting plate and remove pulley. LH rear cover and remove cover.
10. Remove inlet manifold chamber - if fitted.
+ MANIFOLDS & EXHAUST SYSTEMS
cardiagn.com
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber.
OVERHAUL 12-3-97
ENGINE - K SERIES KV6
cardiagn.com
the rear camshaft gears are aligned as
illustrated.
CAUTION: Do not use the camshaft gear
bolts or timing belts to rotate the
crankshaft. Do not use the arrow on the oil
pump body as a timing reference.
M12 7927
12-3-98 OVERHAUL
ENGINE - K SERIES KV6
M12 6672
cardiagn.com
secure with clamp bolt.
OVERHAUL 12-3-99
ENGINE - K SERIES KV6
31. Remove and discard 2 Patchlok bolts securing
tensioner to cylinder block and remove
tensioner.
CAUTION: Exercise great care when
removing bolts, do not apply excessive
torque. If bolts appear to be seized, apply
suitable anti-seize lubricant prior to
removing bolts. DO NOT loosen Allen screw
securing tensioner pulley.
cardiagn.com
replaced if cylinder head is to be removed or
new drive gears, tensioner or coolant pump
are to be fitted. Camshaft timing belts must
27. Remove 5 bolts and 2 pillar bolts securing be stored and handled with care. Always
engine front mounting plate to cylinder block. store a camshaft timing belt on its edge with
28. Remove 2 bolts securing IRD support bracket a bend radius greater than 50 mm (2.0 in).
to engine front mounting plate. Do not use a camshaft timing belt that has
29. With care, release and remove front mounting been twisted or bent double as this will
plate from engine. damage the reinforcing fibres. Do not use a
camshaft timing belt if debris other than belt
dust is found in timing belt covers. Do not
use a camshaft timing belt if partial engine
seizure has occurred. Do not use a
camshaft timing belt if mileage exceeds
72,000 km (45,000 miles). Do not use an oil
or coolant contaminated timing belt, cause
of contamination must be rectified.
12-3-100 OVERHAUL
ENGINE - K SERIES KV6
4. Position timing belt to crankshaft gear.
NOTE: To prevent the timing belt from
disengaging from the crankshaft gear when
fitting, fit a suitable wedge between the belt and
oil pump belt guard.
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otherwise damage to camshafts may occur.
36. Remove and discard bolts retaining front inlet 5. Fit tool LRT-12-197 into each exhaust
camshaft gears to camshafts. camshaft in turn.
37. Remove tools LRT-12-196 from both inlet
camshaft gears and exhaust camshafts.
38. Remove camshaft drive gears and hub
assemblies.
Refit
NOTE: Following front or rear timing belt
refitment, it is possible that, after rotating the
engine and positioning the crankshaft pulley to
the 'SAFE' position, the timing marks on the
rear timing gears may be misaligned. This
misalignment is acceptable provided that the
timing belt refitting procedure was carried out
correctly.
OVERHAUL 12-3-101
ENGINE - K SERIES KV6
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.
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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.
12-3-102 OVERHAUL
ENGINE - K SERIES KV6
35. Position ancillary belt tensioner, fit bolts and
tighten to 25 Nm (18 lbf.ft).
36. Clean LH and RH front timing belt covers.
37. Position LH and RH front timing belt covers, fit
and tighten bolts to 4 Nm (3 lbf.ft).
38. Clean idler pulley, position pulley to engine
front mounting plate and tighten Torx bolt to 45
Nm (33 lbf.ft).
39. Position alternator to front mounting plate.
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. Clean LH rear timing belt cover.
44. Position LH rear timing belt cover, fit and
tighten bolts to 4 Nm (3 lbf.ft).
45. Clean RH rear timing belt cover.
46. Position RH rear timing belt cover, fit bolts and
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tighten to4 Nm (3 lbf.ft).
47. Position heat shield, fit bolts and tighten M6 bolt
to 9 Nm (7 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).
48. Fit inlet manifold chamber - if fitted.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber.
49. Position ancillary drive belt to crankshaft and
alternator pulleys.
50. Position engine mounting front bracket to
engine front plate and tighten bolts to 45 Nm
(33 lbf.ft).
OVERHAUL 12-3-103
ENGINE - K SERIES KV6
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12-3-104 OVERHAUL