ENGINE - 'KV6'

REPAIRS 1 REVISED: 09/97

INLET CAMSHAFT FRONT OIL SEAL - LH BANK
Service repair no - 12.13.40
Remove
1. Remove camshaft timing belt.
2. Fit tool 18G 1747-2 to front timing gear.
CAUTION: TooI must be fitted when
Ioosening or tightening gear retaining
boIt, otherwise damage to camshaft may
occur.
3. Remove bolt retaining front timing gear and
discard.
4. Remove camshaft gear and hub.
5. Remove camshaft oil seal using tool 18G 1768.
ENGINE - 'KV6'
2 REPAIRS REVISED: 09/97
Refit
CAUTION: Front and rear oiI seaIs are not
interchangeabIe. Ensure outer edge of
new oiI seaI and its mating face are cIean
and dry.
1. Clean oil seal recess and camshaft.
2. Lubricate inner lip of new seal with clean
engine oil.
3. Ensure oil seal protector sleeve, tool 18G 1749
is clean. Fit sleeve to camshaft.
4. Position oil seal and using tool 18G 1769 drift
seal into position.
5. Remove tool 18G 1749.
6. Clean camshaft gear and mating face.
7. Fit camshaft gear and hub to camshaft.
8. Fit NEW bolt and tighten sufficiently to allow
gear to rotate without tipping.
9. Fit camshaft timing belt.
INLET CAMSHAFT FRONT OIL SEAL - RH BANK
Service repair no - 12.13.41
Refer to camshaft front oil seal - LH bank.
ENGINE - 'KV6'
REPAIRS 3 REVISED: 09/97
CAMSHAFT REAR OIL SEAL - LH BANK
Service repair no - 12.13.42
Remove
1. Remove camshaft rear timing belt.
2. Remove camshaft oil seal using tool 18G 1768.
Refit
CAUTION: Front and rear oiI seaIs are not
interchangeabIe. Ensure outer edge of
new oiI seaI and its mating face are cIean
and dry.
1. Clean oil seal recess and camshaft.
2. Lubricate inner lip of seal with clean engine oil.
3. Ensure oil seal protector tool 18G 1749 is
clean and fit to camshaft.
4. Locate seal, position 18G 1769 to seal and
drift into position.
5. Remove tool 18G 1749.
6. Fit camshaft rear timing belt.
ENGINE - 'KV6'
4 REPAIRS REVISED: 09/97
CAMSHAFT REAR OIL SEAL - RH BANK
Service repair no - 12.13.43
Remove
1. Remove camshaft rear timing belt.
2. Remove camshaft oil seal using tool 18G 1768.
Refit
CAUTION: Front and rear oiI seaIs are not
interchangeabIe. Ensure outer edge of
new oiI seaI and its mating face are cIean
and dry.
1. Clean oil seal recess and camshaft ends.
2. Lubricate inner lip of seal with clean engine oil.
3. Ensure seal protector tool 18G 1749 is clean
and fit to camshaft .
4. Locate seal, position 18G 1769 to seal and
drift into position.
5. Remove tool 18G 1749.
6. Fit camshaft rear timing belt.
ENGINE - 'KV6'
REPAIRS 5
CRANKSHAFT FRONT OIL SEAL
Service repair no - 12.21.14
Remove
1. Remove camshaft timing belt.
2. Remove crankshaft timing gear.
3. Fit thrust button, tool 18G 1748/3 to end of
crankshaft.
4. Screw tool 18G 1748 into crankshaft front oil
seal.
5. Tighten centre screw of tool 18G1748 to
remove seal.
6. Discard crankshaft front oil seal.
7. Remove thrust button from crankshaft.
Refit
1. Using a lint free cloth, thoroughly clean oil seal
recess in oil pump and running surface on
crankshaft.
2. Lubricate sealing surfaces of new seal with
clean engine oil.
3. Fit oil seal guide, from seal kit, over end of
crankshaft.
4. Position new seal on crankshaft up against oil
pump housing. Drift seal into place using tool
18G 1750.
5. Remove tool 18G 1750 and oil seal guide.
6. Clean crankshaft gear.
7. Fit gear to crankshaft.
8. Fit camshaft timing belt.
ENGINE - 'KV6'
6 REPAIRS REVISED: 09/97
CRANKSHAFT FRONT OIL SEAL - AIR
CONDITIONING
Service repair no - 12.21.14/20
Remove
1. Remove camshaft timing belt.
2. Remove crankshaft timing gear.
3. Fit thrust button, tool 18G 1748/3 to end of
crankshaft.
4. Screw tool 18G 1748 into crankshaft front oil
seal.
5. Tighten centre screw of tool 18G1748 to
remove seal.
6. Discard crankshaft front oil seal.
7. Remove thrust button from crankshaft.
Refit
1. Using a lint free cloth, thoroughly clean oil seal
recess in oil pump and running surface on
crankshaft.
2. Lubricate sealing surfaces of new seal with
clean engine oil.
3. Fit oil seal guide, from seal kit, over end of
crankshaft.
4. Position new seal on crankshaft up against oil
pump housing. Drift seal into place using tool
18G 1750.
5. Remove tool 18G 1750 and oil seal guide.
6. Clean crankshaft gear.
7. Fit crankshaft gear to crankshaft.
8. Fit camshaft timing belt.
ENGINE - 'KV6'
REPAIRS 7
CRANKSHAFT REAR OIL SEAL - MANUAL
Service repair no - 12.21.20
Remove
1. Remove flywheel.
2. Remove 5 bolts securing crankshaft rear oil
seal to cylinder block.
3. Remove crankshaft rear oil seal.
Refit
1. Clean cylinder block face and oil seal running
surface on crankshaft.
2. Lubricate oil seal running surface with clean
engine oil.
3. Position oil seal protector tool 18G 1108 to
crankshaft.
4. Position oil seal to crankshaft.
5. Clean bolts and apply Loctite 242 to first 3
threads, fit bolts and tighten to 9 Nm.
6. Remove oil seal protector.
7. Fit flywheel.
ENGINE - 'KV6'
8 REPAIRS
CRANKSHAFT REAR OIL SEAL - AUTOMATIC
Service repair no - 12.21.20
Remove
1. Remove converter drive plate
2. Remove 5 bolts securing crankshaft rear oil
seal to cylinder block.
3. Remove crankshaft rear oil seal.
Refit
1. Clean cylinder block face and oil seal running
surface on crankshaft.
2. Lubricate oil seal running surface with clean
engine oil.
3. Position oil seal protector 18G 1108 to
crankshaft.
4. Position oil seal to crankshaft.
5. Clean bolts and apply Loctite 242 to first 3
threads, fit bolts and tighten to 9 Nm.
6. Remove oil seal protector.
7. Refit drive plate.
ENGINE - 'KV6'
REPAIRS 9
CYLINDER HEAD GASKET - LH
Service repair no - 12.29.02
Remove
1. Remove camshaft timing belt.
2. Depressurise fuel system.
3. Drain cooling system.
CAUTION: Remove drain pIug from
cyIinder bIock to ensure retained cooIant
does not enter the intake ports in the
cyIinder head.
4. Remove front inlet camshaft gear bolt.
5. Remove gear and hub assembly.
6. Remove 4 bolts securing timing belt cover
backplate.
7. Remove backplate.
8. Disconnect 3 h.t. leads from spark plugs.
9. Release leads from clips.
10. Remove 2 breather hoses from LH cam cover.
11. Remove 5 bolts securing coil mounting plate to
inlet manifold.
12. Disconnect 3 coil multiplugs and move coil and
mounting plate assembly aside.
13. Release clips and disconnect manifold and top
hose coolant bleed hoses from 'T' piece and
move expansion tank pipe aside.
ENGINE - 'KV6'
10 REPAIRS
14. Remove bolt securing fuel return pipe to inlet
manifold.
15. Release fuel feed and return pipes from clips.
16. Disconnect oxygen sensor, coolant
temperature sensor and camshaft sensor
multiplugs.
17. Remove bolt securing harness bracket to
camshaft cover.
18. Release harness clip from engine lifting
bracket.
19. Remove 4 bolts securing fuel rail.
20. Release injectors from manifolds, disconnect
multiplug from intake air temperature sensor
and carefully lay fuel rail and injectors aside.
ENGINE - 'KV6'
REPAIRS 11
21. Release clips securing coolant bleed hose to
manifolds, release and remove hose.
22. Progressively loosen and remove 14 bolts
securing camshaft cover.
23. Remove camshaft cover and gasket.
24. Remove 2 nuts securing front manifold flange
to rear manifold flange.
25. Progressively loosen and remove 8 cylinder
head bolts.
26. Using assistance, remove cylinder head
assembly.
27. Remove and discard cylinder head gasket and
exhaust manifold flange gasket.
CAUTION: Do not rotate crankshaft with
cyIinder head removed. PIace cyIinder
head on bIocks of wood to avoid
damaging vaIves.
ENGINE - 'KV6'
12 REPAIRS
Refit
1. Clean manifold flange mating faces.
2. Thoroughly clean cylinder block and cylinder
head mating faces.
3. Thoroughly clean cylinder head bolts and wipe
dry.
4. Lightly lubricate threads and under heads of
bolts with clean engine oil.
5. Ensure locating dowels are in cylinder block.
6. Fit new cylinder head gasket onto cylinder
block with word 'TOP' uppermost.
7. Fit new gasket to exhaust manifold flange.
8. Using assistance, fit cylinder head, carefully
locating front manifold to rear manifold flange
and cylinder head to dowels.
9. Carefully enter cylinder head bolts, DO NOT
DROP. Screw bolts into place by hand.
10. Tighten cylinder head bolts progressively in
sequence shown to 25 Nm.
Tighten bolts in sequence shown a further 90.
11. Clean mating surfaces of camshaft cover and
carrier.
12. Clean inside of camshaft cover. lf necessary,
wash oil separator gauze and blow dry.
CAUTION: When fitting new camshaft
cover gasket ensure arrows point towards
inIet manifoId.
13. Fit gasket and position camshaft cover to
carrier. Fit bolts and tighten progressively in
sequence shown to 9 Nm.
14. Fit manifold nuts and tighten to 45 Nm.
15. Fit bleed hose and secure with clips.
16. Remove and discard lower 'O' rings from
injectors.
17. Clean injectors and injector locations in fuel
rail.
18. Lubricate new 'O' rings with clean engine oil
and fit to injectors.
19. Position fuel rail assembly, connect inlet air
temperature sensor, secure injectors to
manifolds. Fit bolts securing fuel rail and
tighten to 9 Nm.
20. Secure harness clip to engine lifting bracket.
21. Position harness bracket to camshaft cover, fit
bolt and tighten to 9 Nm.
22. Connect camshaft sensor, coolant temperature
sensor and oxygen sensor multiplugs.
23. Secure fuel pipes to clips.
24. Fit bolt securing fuel return pipe to inlet
manifold and tighten to 9 Nm .
25. Position expansion tank pipe, connect bleed
hoses to 'T' piece and secure with clips.
26. Connect coil multiplugs, align mounting plate to
manifold, fit bolts and tighten to 9 Nm.
27. Fit breather hoses to camshaft cover.
28. Connect h.t. leads to spark plugs and secure
leads to clips.
29. Clean timing cover backplate bolts and apply
Loctite 242 to first 3 threads.
30. Ensure seal is fitted correctly to timing cover
backplate. Position backplate, fit bolts and
tighten to 9 Nm.
31. Clean and thoroughly dry timing gear and hub.
32. Fit timing gear and hub and fit bolt. Tighten bolt
sufficiently to allow gear to rotate without
tipping.
33. Fit camshaft timing belt.
34. Refill cooling system.
ENGINE - 'KV6'
REPAIRS 13
CYLINDER HEAD GASKET - RH
Service repair no - 12.29.03
Remove
1. Remove exhaust manifolds.
2. Remove camshaft timing belt.
3. Depressurise fuel system.
4. Drain cooling system.
CAUTION: Remove drain pIug from
cyIinder bIock to ensure retained cooIant
does not enter the intake ports in the
cyIinder head.
5. Remove rear inlet camshaft gear bolt.
6. Remove gear and hub assembly.
7. Remove 4 bolts securing timing belt cover
backplate.
8. Remove backplate.
9. Disconnect 3 h.t. leads from spark plugs.
10. Release leads from clips.
11. Remove 2 breather hoses from LH cam cover.
12. Remove breather hose from RH camshaft
cover.
13. Remove 5 bolts securing coil mounting plate to
inlet manifold.
14. Disconnect 3 coil multiplugs and move coil and
mounting plate assembly aside.
15. Release clip and disconnect manifold coolant
bleed hose from 'T' piece.
ENGINE - 'KV6'
14 REPAIRS REVISED: 09/97
16. Remove bolt securing fuel return pipe to inlet
manifold.
17. Release fuel feed and return pipes from clips.
18. Release oil pressure switch and oil
temperature sensor harness multiplug from
bracket on cylinder head.
19. Release harness clip from engine lifting
bracket.
20. Remove 4 bolts securing fuel rail.
21. Release injectors from manifolds, and carefully
lay fuel rail and injectors aside.
ENGINE - 'KV6'
REPAIRS 15
22. Release clips securing coolant bleed hose to
manifolds, release and remove hose.
23. Remove bolt securing harness bracket to
camshaft cover.
24. Progressively loosen and remove 14 bolts
securing camshaft cover.
25. Remove camshaft cover and gasket.
26. Progressively loosen and remove 8 cylinder
head bolts.
NOTE: Height of engine wiII need to be
adjusted on jack to faciIitate removaI of
head boIts.
27. Using assistance, remove cylinder head
assembly.
28. Remove and discard cylinder head gasket.
CAUTION: Do not rotate crankshaft with
cyIinder head removed. PIace cyIinder
head on bIocks of wood to avoid
damaging vaIves.
ENGINE - 'KV6'
16 REPAIRS
Refit
1. Thoroughly clean cylinder block and cylinder
head mating faces.
2. Thoroughly clean cylinder head bolts and wipe
dry.
3. Lightly lubricate threads and under heads of
bolts with clean engine oil.
4. Ensure locating dowels are in cylinder block.
5. Fit new cylinder head gasket onto cylinder
head with word 'TOP' uppermost.
6. Using assistance, fit cylinder head, carefully
locating cylinder head to dowels.
7. Carefully enter cylinder head bolts, DO NOT
DROP. Screw bolts into place by hand.
8. Tighten cylinder head bolts progressively in
sequence shown to 25 Nm.
Tighten bolts in sequence shown a further 90.
9. Clean mating surfaces of camshaft cover and
carrier.
10. Clean inside of camshaft cover. lf necessary,
wash oil separator gauze and blow dry.
CAUTION: When fitting new camshaft
cover gasket ensure arrows point towards
inIet manifoId.
11. Fit gasket and position camshaft cover to
carrier. Fit bolts and tighten progressively in
sequence shown to 9 Nm.
12. Fit bleed hose and secure with clips.
13. Remove and discard lower 'O' rings from
injectors.
14. Clean injectors and injector locations in fuel
rail.
15. Lubricate new 'O' rings with clean engine oil
and fit to injectors.
16. Position fuel rail assembly and secure injectors
to manifolds. Fit bolts securing fuel rail and
tighten to 9 Nm.
17. Secure harness clip to engine lifting bracket.
18. Position harness bracket to camshaft cover, fit
bolt and tighten to 9 Nm.
19. Secure oil pressure switch and oil temperature
sensor harness multiplug to bracket on cylinder
head.
20. Secure fuel pipes to clips.
21. Fit bolt securing fuel return pipe to inlet
manifold and tighten to 9 Nm .
22. Connect bleed hose to 'T' piece and and
secure with clip.
23. Connect coil multiplugs, align mounting plate to
manifold, fit bolts and tighten to 9 Nm.
ENGINE - 'KV6'
REPAIRS 17
24. Fit breather hoses to LH and RH camshaft
covers.
25. Connect h.t. leads to spark plugs and secure
leads to clips.
26. Clean timing cover backplate bolts and apply
Loctite 242 to first 3 threads.
27. Ensure seal is fitted correctly to timing cover
backplate. Position backplate, fit bolts and
tighten to 9 Nm.
28. Clean and thoroughly dry timing gear and hub.
29. Fit timing gear and hub and fit bolt. tighten bolt
sufficiently to allow gear to rotate without
tipping.
30. Fit camshaft timing belt.
31. Fit exhaust manifold.
32. Refill cooling system.
CAMSHAFT COVER GASKET - LH
Service repair no - 12.29.40
Remove
1. Remove engine acoustic cover,
2. Remove 2 bolts securing spark plug cover to
camshaft cover. Remove cover.
ENGINE - 'KV6'
18 REPAIRS
3. Release 2 breather hoses from LH camshaft
cover.
4. Disconnect 3 h.t. leads from spark plugs.
5. Remove bolt securing harness bracket to
camshaft cover.
6. Progressively loosen and remove 14 bolts
securing camshaft cover.
7. Remove camshaft cover and gasket.
ENGINE - 'KV6'
REPAIRS 19
Refit
1. Clean mating surfaces of camshaft cover and
carrier.
2. Clean inside of camshaft cover. lf necessary,
wash oil separator gauze and blow dry.
CAUTION: When fitting new gasket ensure
arrows point towards inIet manifoId.
3. Fit new gasket and position camshaft cover to
carrier. Fit bolts and working in the sequence
illustrated, tighten progressively to 9 Nm.
4. Position harness bracket to camshaft cover
and tighten bolt to 8 Nm.
5. Connect spark plug leads and secure breather
hoses to camshaft cover.
6. Position spark plug cover and tighten bolts to 4
Nm.
7. Fit engine acoustic cover,
ENGINE - 'KV6'
20 REPAIRS
CAMSHAFT COVER GASKET - RH
Service repair no - 12.29.41
Remove
1. Remove 4 bolts securing manifold chamber
support brackets. Remove brackets.
2. Release breather hose from camshaft cover.
3. Disconnect h.t. leads from spark plugs.
4. Remove bolt securing harness bracket to
camshaft cover.
5. Progressively loosen and remove 14 bolts
securing camshaft cover.
6. Remove camshaft cover and gasket.
ENGINE - 'KV6'
REPAIRS 21
Refit
1. Clean mating surfaces of camshaft cover and
carrier.
2. Clean inside of camshaft cover. lf necessary,
wash oil separator gauze and blow dry.
CAUTION: When fitting new gasket ensure
arrows point towards inIet manifoId.
3. Fit new gasket and position camshaft cover to
carrier. Fit bolts and working in sequence
illustrated, tighten progressively to 9 Nm.
4. Position harness bracket to camshaft cover
and tighten bolt to 8 Nm.
5. Connect spark plug leads and secure breather
hose to camshaft cover.
6. Fit manifold support brackets and tighten bolts
to 25 Nm.
ENGINE AND MANUAL GEARBOX
Service repair no - 12.37.01/99
Remove
1. Release spring clips retaining bonnet struts.
2. Disconnect struts and tie bonnet back.
3. Remove air cleaner assembly.
4. Remove battery.
5. Remove inlet manifold chamber.
6. Raise front of vehicle.
WARNING: Support on safety stands.
7. Remove radiator assembly.
8. Remove 2 screws securing spark plug cover.
9. Remove cover.
ENGINE - 'KV6'
22 REPAIRS
10. Remove bolt securing PAS pipe to engine
bracket.
11. Release coolant hose from clip on PAS pipe.
12. Release clip and disconnect hose from
expansion tank. 13. Loosen 3 bolts securing PAS pump pulley.
14. Using a 25 mm spanner, raise drive belt
tensioner and release drive belt from alternator
and PAS pump pulleys.
15. Remove drive belt.
NOTE: On modeIs with air conditioning
drive beIt remains captive.
ENGINE - 'KV6'
REPAIRS 23
16. Remove 3 bolts securing PAS pump pulley.
17. Remove pulley.
18. Remove 3 bolts securing PAS pump.
19. Release and move PAS pump aside.
20. Release 2 engine harness multiplugs from
bracket on RH inner wing. Disconnect
multiplugs.
21. Release harness clip from bracket.
22. Remove bolt securing rear steady bar to body
bracket
23. Remove bolt securing steady bar to engine
bracket and collect special nut.
24. Remove steady bar.
ENGINE - 'KV6'
24 REPAIRS
25. Remove bolt securing coolant pipe to steady
bar bracket.
26. Release harness clip from steady bar bracket.
27. Remove 2 bolts securing steady bar bracket to
gearbox.
28. Remove steady bar bracket.
29. Slacken clip securing heater return hose to
pipe and disconnect hose.
30. Position cloth to absorb fuel spillage.
31. Disconnect fuel feed and return hoses.
CAUTION: PIug the connections.
32. Remove cloth.
33. Disconnect 2 engine harness multiplugs.
ENGINE - 'KV6'
REPAIRS 25
34. Remove fuse box cover and main fuse cover.
35. Remove Torx screw securing fuse box main
battery feed lead terminal.
36. Remove lead access panel from fuse box and
release lead from fuse box.
37. Remove battery positive lead terminal bolt and
release fuse box main feed lead.
38. Disconnect 2 multiplugs from ECM.
39. Remove bolt securing ECM and remove ECM.
40. Remove 4 bolts securing battery tray and
remove battery tray.
ENGINE - 'KV6'
26 REPAIRS
41. Remove 3 bolts securing air cleaner bracket
and remove bracket.
42. Remove bolt securing earth lead to gearbox.
43. Remove road wheel(s).
44. Drain gearbox oil.
45. Drain engine oil.
46. Remove 3 bolts securing RH under wing
splash shield. Collect spacer and remove
shield.
47. Remove 4 bolts securing compressor to
mounting bracket.
48. Release compressor and lay aside.
49. Remove compressor heatshield.
ENGINE - 'KV6'
REPAIRS 27
50. Remove 8 bolts securing centre beam to front
and rear crossmembers.
51. Remove centre beam.
52. Remove 3 bolts securing front steady bar
bracket to front crossmember.
53. Remove 2 bolts securing steady bar bracket to
gearbox.
54. Remove steady bar and bracket assembly.
55. Remove 'R' clip retaining clutch slave cylinder
push rod clevis pin.
56. Remove washer and clevis pin.
57. Remove 2 bolts securing slave cylinder to front
engine mounting bracket.
58. Position slave cylinder aside.
ENGINE - 'KV6'
28 REPAIRS
59. Release exhaust front pipe from mounting.
60. Remove 3 nuts securing exhaust front pipe to
manifold.
61. Release front pipe from manifold.
62. Remove and discard gasket.
63. Remove selector rod roll pin cover.
64. Remove selector rod roll pin.
65. Remove selector steady rod bolt.
66. Release steady rod and selector rod from
gearbox.
67. Collect 2 steady rod washers.
68. Remove LH and RH drive shaft assemblies.
69. Use a hoist and connect adjustable lifting
bracket 18G 1598 to engine.
70. Raise hoist to take weight of engine without
exerting load on mountings.
71. Loosen through bolt securing engine RH
mounting bracket to body.
72. Remove 2 bolts securing engine mounting
bracket to engine.
73. Swivel mounting bracket away from engine and
tighten through bolt to hold bracket clear of
engine.
ENGINE - 'KV6'
REPAIRS 29 REVISED: 09/97
74. Loosen clip and disconnect expansion tank
hose from coolant pipe.
75. Remove 2 bolts securing coolant pipe to front
crossmember.
76. Move coolant pipe aside and remove 2 bolts
securing engine front mounting to
crossmember.
77. Remove 2 bolts securing engine front mounting
bracket to gearbox.
78. Release and remove mounting and mounting
bracket assembly.
79. Remove top nut from engine rear mounting.
80. Loosen 2 bolts securing engine rear mounting
to crossmember.
81. Raise engine, release clip and disconnect
heater feed hose from rear of cylinder block.
ENGINE - 'KV6'
30 REPAIRS
82. Raise hoist, tilt engine with gearbox as low as
possible and using assistance manoeuvre and
lift engine and gearbox from vehicle.
Refit
1. Using assistance, lower engine and gearbox
assembly into engine bay.
2. Connect heater feed hose and secure with clip.
3. Lower engine onto rear mounting.
4. Position front mounting and bracket assembly,
fit bolts securing bracket to engine and tighten
to 85 Nm.
5. Align bracket to front crossmember, fit bolts
and tighten to 45 Nm.
6. Loosen RH engine mounting through bolt. align
mounting bracket to engine fit bolts bolts and
tighten to 85 Nm. DO NOT tighten through bolt.
7. Lower hoist, disconnect and remove lifting
bracket 18G 1598.
8. Fit nut to rear mounting but DO NOT tighten.
9. Tighten bolts securing rear engine mounting
bracket to crossmember to 45 Nm.
10. Align coolant pipe to front crossmember and
tighten bolts.
11. Connect coolant hose and tighten clip.
12. Fit LH and RH drive shaft assemblies.
13. Position gearbox steady rod washers and
connect rod. Fit bolt and tighten to 25 Nm.
14. Connect gear selector rod and align holes in
shaft and rod. Fit new roll pin.
15. Fit roll pin retaining clip.
16. Clean exhaust manifold and front pipe mating
faces and fit new gasket.
17. Connect front pipe to manifold, fit nuts and
tighten to 35 Nm.
18. Connect exhaust mounting.
19. Position clutch slave cylinder to engine front
mounting bracket, fit and tighten bolts to 22
Nm.
20. Clean push rod clevis pin and smear with
grease.
21. Align push rod to lever and fit clevis pin,
washer and 'R' clip.
22. Position front steady bar and bracket
assembly.
23. Fit bolts securing bracket to gearbox and
tighten to 85 Nm.
24. Fit bolts securing steady bracket to front
crossmember and tighten to 60 Nm
ENGINE - 'KV6'
REPAIRS 31
25. Position centre beam, fit bolts and tighten to 45
Nm.
26. Fit road wheel(s) and tighten nuts to correct
torque.
27. Remove stand(s) and lower vehicle.
28. Position earth lead to gearbox and tighten bolt.
29. Position air cleaner bracket and tighten bolts.
30. Position battery tray and tighten bolts.
31. Fit ECM, tighten bolt and connect multiplugs.
32. Position main battery feed lead to battery
terminal and fit bolt.
33. Locate battery feed lead to fuse box, fit and
tighten Torx screw.
34. Fit access panel, main fuse cover and fuse box
cover.
35. Connect engine harness multiplugs
36. Remove plugs from fuel feed and return hoses
and connect hoses.
37. Fit rear steady bar bracket, fit bolts and tighten
to 85 Nm.
38. Secure harness clip to bracket.
39. Position coolant pipe bracket, fit and tighten
bolt to 10 Nm.
40. Fit steady bar and fit bolt securing steady bar
to body.
41. Align steady bar to bracket, fit through bolt and
special nut. DO NOT tighten bolts.
42. Tighten all engine mounting and steady bar
fixings in correct sequence to correct torque.
43. Connect multiplugs and secure to bracket on
RH suspension turret.
44. Secure harness to bracket.
45. Align compressor to mounting bracket, position
heatshield, fit bolts and tighten to 25 Nm.
46. Fit splash shield, align PAS hose clip, fit spacer
to front bolt and tighten bolts.
47. Position PAS pump to bracket, fit bolts and
tighten 25 Nm.
48. Fit PAS pump pulley and fit bolts.
49. Fit drive belt to crankshaft pulley and
compressor pulley if fitted.
50. Using a 25 mm spanner raise belt tensioner
and connect drive belt to steering pump and
alternator pulleys. Ensure drive belt is correctly
located in pulley grooves.
51. Tighten PAS pulley bolts to 9 Nm.
52. Connect coolant hose to expansion tank and
secure with clip.
53. Clip hose to PAS pipe.
54. Align PAS pipe clip to engine bracket and fit
and tighten bolt.
55. Position spark plug cover and fit and tighten
bolts.
56. Fit radiator.
57. Remove stand(s) and lower vehicle.
58. Fit manifold chamber.
59. Fit battery.
60. Fit air cleaner assembly.
61. Release bonnet and secure stays to support
bonnet.
62. Fill gearbox with correct quantity and grade of
oil.
63. Fill engine with correct quantity and grade of
oil.
64. Fill cooling system.
ENGINE - 'KV6'
32 REPAIRS
ENGINE AND AUTOMATIC GEARBOX
Service repair no - 12.37.01/99
Remove
1. Release spring clips retaining bonnet struts.
2. Disconnect struts and tie bonnet back.
3. Remove air cleaner assembly.
4. Remove battery.
5. Remove inlet manifold chamber.
6. Raise front of vehicle.
WARNING: Support on safety stands.
7. Remove radiator assembly.
8. Remove 2 screws securing spark plug cover.
9. Remove cover.
10. Remove bolt securing PAS pipe to engine
bracket.
11. Release coolant hose from clip on PAS pipe.
12. Release clip and disconnect hose from
expansion tank.
ENGINE - 'KV6'
REPAIRS 33
13. Loosen 3 bolts securing PAS pump pulley.
14. Using a 25 mm spanner, raise drive belt
tensioner and release drive belt from alternator
and PAS pump pulleys.
15. Remove drive belt.
NOTE: On modeIs with air conditioning
drive beIt remains captive.
16. Remove bolts securing PAS pump pulley.
17. Remove pulley.
18. Remove 3 bolts securing PAS pump.
19. Release and move PAS pump aside.
20. Release 4 engine harness multiplugs from
bracket on RH inner wing. Disconnect
multiplugs.
21. Release harness clip from bracket.
ENGINE - 'KV6'
34 REPAIRS
22. Disconnect Lucar from starter solenoid.
23. Remove nut and disconnect battery lead from
starter solenoid.
24. Remove 2 bolts securing starter motor.
25. Remove starter motor.
26. Remove bolt securing rear steady bar to body
bracket
27. Remove bolt securing steady bar to engine
bracket and collect special nut.
28. Remove steady bar.
29. Remove bolt securing coolant pipe to steady
bar bracket.
30. Remove 2 bolts securing steady bar brackets
to gearbox.
31. Remove steady bar brackets.
32. Slacken clip securing heater return hose to
coolant pipe and disconnect hose.
33. Position cloth under fuel filter to absorb fuel
spillage.
34. Disconnect fuel feed and return hoses.
CAUTION: PIug the connections.
35. Remove cloth.
ENGINE - 'KV6'
REPAIRS 35
36. Release 5 multiplugs from selector cable
bracket.
37. Remove nut securing selector lever to selector
shaft and release lever from shaft.
38. Remove 2 bolts securing selector cable
bracket to gearbox. Move bracket clear of
gearbox.
39. Disconnect engine harness multiplug on LH
side of engine.
40. Remove fuse box cover and main fuse cover.
41. Remove Torx screw securing fuse box main
battery feed lead terminal.
42. Remove lead access panel from fuse box and
release lead from fuse box.
43. Remove battery positive lead terminal bolt and
release fuse box main feed lead.
ENGINE - 'KV6'
36 REPAIRS
44. Disconnect 2 multiplugs from ECM.
45. Remove bolt securing ECM and remove ECM.
46. Remove 4 bolts securing battery tray and
remove battery tray.
47. Remove 3 bolts securing air cleaner bracket
and remove bracket.
48. Remove bolt securing earth lead to gearbox.
49. Remove bolt securing lifting bracket to
gearbox.
50. Remove bracket.
51. Remove road wheel(s).
ENGINE - 'KV6'
REPAIRS 37
52. Drain gearbox fluid.
53. Drain engine oil.
54. Release harness clip from gearbox dipstick
tube.
55. Remove bolt securing dipstick tube bracket.
56. Remove bolt securing dipstick tube.
57. Remove dipstick tube, remove and discard 'O'
ring.
CAUTION: PIug gearbox.
58. Disconnect 2 oil cooler unions.
59. Remove and discard 2 oil cooler union 'O'
rings.
CAUTION: PIug the connections.
60. Loosen clip securing hose to oil cooler.
61. Remove 2 bolts securing oil cooler bracket to
engine front mounting bracket.
62. Remove oil cooler.
ENGINE - 'KV6'
38 REPAIRS
63. Remove 3 bolts securing RH under wing
splash shield. Collect spacer and remove
shield.
64. Remove 4 bolts securing compressor to
mounting bracket.
65. Release compressor and lay aside.
66. Remove compressor heatshield.
67. Remove 8 bolts securing centre beam to front
and rear cross-members.
68. Remove centre beam.
ENGINE - 'KV6'
REPAIRS 39
69. Remove 3 bolts securing front steady bar
bracket to front crossmember.
70. Remove 2 bolts securing steady bar bracket to
gearbox.
71. Remove steady bar and bracket assembly.
72. Release mounting rubber from exhaust front
pipe.
73. Remove 3 nuts securing exhaust front pipe to
manifold.
74. Release front pipe from manifold.
75. Remove and discard gasket.
76. Remove LH and RH drive shafts.
77. Remove nut securing LH tie rod to front
crossmember.
78. Remove dished washer and bush
79. Remove 2 bolts securing LH tie rod to lower
arm.
80. Remove tie rod.
81. Remove spacer, bush and dished washer from
tie rod.
ENGINE - 'KV6'
40 REPAIRS
82. Use a hoist and connect adjustable lifting
bracket 18G 1598 to engine.
83. Raise hoist to take weight of engine without
exerting load on mountings.
84. Loosen through bolt securing engine RH
mounting bracket to body.
85. Remove 2 bolts securing engine mounting
bracket to engine.
86. Swivel mounting bracket away from engine and
tighten through bolt to hold bracket clear of
engine.
87. Loosen clip and disconnect expansion tank
hose from coolant pipe.
88. Remove 2 bolts securing coolant pipe to front
crossmember.
89. Move coolant pipe aside and remove 2 bolts
securing engine front mounting to
crossmember.
90. Remove 2 bolts securing engine front mounting
bracket to gearbox.
91. Release and remove mounting and mounting
bracket assembly.
92. Remove top nut from engine rear mounting.
93. Remove 3 bolts securing engine rear mounting
bracket to engine.
94. Remove bracket.
ENGINE - 'KV6'
REPAIRS 41 REVISED: 09/97
95. Raise engine, release clip and disconnect
heater feed hose from rear of cylinder block.
96. Raise hoist, tilt engine with gearbox as low as
possible.
97. Using assistance manoeuvre and lift engine
and gearbox from vehicle.
Refit
1. Using assistance, lower engine and gearbox
assembly into engine bay.
2. Connect heater hose to cylinder block and
secure with clip.
3. Position rear engine mounting bracket, fit bolts
and tighten to 85 Nm.
4. Position front mounting and bracket assembly,
fit bolts securing bracket to engine and tighten
to 85 Nm.
5. Align bracket to front crossmember, fit bolts
and tighten to 45 Nm.
6. Loosen RH engine mounting through bolt. align
mounting bracket to engine fit bolts and tighten
to 85 Nm. DO NOT tighten through bolt.
7. Lower hoist, disconnect and remove lifting
bracket 18G 1598.
8. Fit nut to rear mounting but DO NOT tighten.
9. Align coolant pipe to front crossmember and
tighten bolts.
10. Connect coolant hose and tighten clip.
11. Fit plain washer, dished washer, spacer and
bush to tie rod.
12. Fit tie rod, fit bolts securing tie rod to lower arm
and tighten to 170 Nm.
13. Fit outer rubber and dished washer to rod, fit
nut and tighten to 90 Nm.
14. Fit LH and RH drive shaft assemblies.
15. Clean exhaust manifold and front pipe mating
faces and fit new gasket.
16. Connect front pipe to manifold, fit nuts and
tighten to 35 Nm.
17. Connect exhaust mounting rubber.
18. Position front steady bar and bracket
assembly.
19. Fit bolts securing bracket to gearbox and
tighten to 85 Nm.
20. Fit bolts securing steady bracket to front
crossmember and tighten to 60 Nm.
21. Position centre beam, fit bolts and tighten to 60
Nm.
22. Align compressor to mounting bracket, position
heatshield, fit bolts and tighten to 25 Nm.
23. Fit RH splash shield, align PAS hose clip, fit
spacer to front bolt and tighten bolts.
ENGINE - 'KV6'
42 REPAIRS
24. Fit oil cooler, align oil cooler bracket to engine
front mounting bracket, fit bolts and tighten to
45 Nm.
25. Tighten hose clip.
26. Clean oil cooler pipe unions.
27. Lubricate NEW 'O' rings with clean
transmission fluid and fit to pipes.
28. Connect pipes to gearbox and tighten unions to
17 Nm.
29. Fit road wheel(s) and tighten nuts to correct
torque.
30. Remove stand(s) and lower vehicle.
31. Position lifting bracket to gearbox and tighten
bolt.
32. Position earth lead to gearbox and tighten bolt.
33. Clean dipstick tube and fit NEW 'O' ring.
Remove plug from gearbox, clean tube location
in gearbox and fit tube.
34. Fit bolt securing dipstick tube and tighten to 8
Nm.
35. Fit bolt securing dipstick tube bracket and
tighten to 85 Nm.
36. Secure harness clip to bracket.
37. Position air cleaner bracket and tighten bolts.
38. Position battery tray and tighten bolts.
39. Fit ECM, tighten bolt and connect multiplugs.
40. Position main battery feed lead to battery
terminal and fit bolt.
41. Locate battery feed lead to fuse box, fit and
tighten Torx screw.
42. Fit access panel, main fuse cover and fuse box
cover.
43. Connect engine harness multiplugs
44. Position selector cable bracket, fit bolts and
tighten to 22 Nm.
45. Connect selector lever to selector shaft, fit nut
and tighten to 12 Nm.
46. Secure multiplugs to selector cable bracket.
47. Remove plugs from fuel feed and return hoses
and connect hoses.
48. Fit rear steady bar bracket, fit bolts and tighten
to 85 Nm.
49. Secure harness clip to bracket.
50. Position coolant pipe bracket, fit and tighten
bolt to 10 Nm.
51. Fit steady bar and fit bolt securing steady bar
to body.
52. Align steady bar to bracket, fit through bolt and
special nut. DO NOT tighten bolts.
53. Tighten all engine mounting and steady bar
fixings in correct sequence.
54. Clean mating faces of starter motor and
gearbox.
55. Fit starter motor and fit rear bolt but do not
tighten.
56. Fit front retaining bolt.
57. Tighten both retaining bolts to 45 Nm.
58. Connect battery cable to starter solenoid, fit nut
and tighten to 4 Nm .
59. Connect Lucar connection to solenoid.
60. Connect multiplugs and secure to bracket on
RH inner wing.
61. Secure harness to bracket.
62. Position PAS pump to bracket, fit bolts and
tighten 25 Nm.
63. Fit PAS pump pulley and fit bolts.
64. Fit drive belt to crankshaft pulley and
compressor pulley if fitted.
65. Using a 25 mm spanner raise belt tensioner
and connect drive belt to steering pump and
alternator pulleys. Ensure drive belt is correctly
located in pulley grooves.
66. Tighten PAS pulley bolts to 9 Nm.
67. Connect coolant hose to expansion tank and
secure with clip.
68. Clip hose to PAS pipe.
69. Align PAS pipe clip to engine bracket and fit
and tighten bolt.
70. Position spark plug cover and fit and tighten
bolts.
71. Fit radiator.
72. Remove stand(s) and lower vehicle.
73. Fit manifold chamber.
74. Fit battery.
75. Fit air cleaner assembly.
76. Release bonnet and secure stays to support
bonnet.
77. Fill gearbox with correct quantity and grade of
fluid.
78. Fill engine with correct quantity and grade of
oil.
79. Fill cooling system.
ENGINE - 'KV6'
REPAIRS 43
ENGINE MOUNTING - FRONT
Service repair no - 12.45.02
Remove
1. Disconnect battery earth lead.
2. Remove underbelly panel.
3. Position jack under gearbox and support
weight of power unit.
CAUTION: Use a bIock of wood or hard
rubber pad to protect sump.
4. Remove 2 bolts securing heater outlet pipe to
front cross-member.
5. Position heater outlet pipe rearwards.
6. Release top hose from front clip.
7. Remove 'R' clip and clevis pin securing push
rod to clutch lever.
8. Remove nut securing engine mounting to
engine bracket.
9. Remove 2 bolts securing engine mounting to
front cross-member.
10. Remove 2 bolts securing mounting bracket to
bell housing.
11. Release engine mounting from bracket and
remove mounting.
ENGINE - 'KV6'
44 REPAIRS
Refit
1. Engage engine mounting in bracket and
position mounting on front cross-member.
2. Align slave cylinder bracket fixing.
3. Fit bolts securing mounting bracket to bell
housing and tighten to 85 Nm.
4. Fit bolts securing mounting to front
cross-member and tighten to 45 Nm.
5. Fit nut securing mounting to bracket and
tighten to 85 Nm.
6. Remove jack.
7. Fit top hose into clip.
8. Position heater outlet pipe and tighten bolts.
9. Fit underbelly panel.
10. Connect battery earth lead.
ENGINE MOUNTING - RH
Service repair no - 12.45.03
Remove
1. Position jack under engine and support weight
of power unit.
CAUTION: Use a bIock of wood or hard
rubber pad to protect sump.
2. Remove bolt and plain washer securing engine
RH mounting to body bracket and retrieve
special nut.
3. Remove 2 bolts securing RH mounting to
engine bracket.
4. Release RH mounting from body bracket and
remove.
ENGINE - 'KV6'
REPAIRS 45
Refit
1. Engage RH mounting in body bracket and
position mounting on front beam.
2. Fit through bolt to secure mounting to body
bracket, engage special nut around peg, do not
tighten.
3. Fit bolts securing mounting to engine bracket,
tighten to 75 Nm.
4. Tighten through bolt to 45 Nm.
5. Remove support jack.
ENGINE MOUNTING - REAR
Service repair no - 12.45.08
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Using extension and universal, remove locknut
from top of engine mounting.
4. Position jack under gearbox and support
weight of power unit.
5. Remove bolt securing engine mounting bracket
to engine flange and 2 bolts to differential
housing.
6. Remove engine mounting bracket.
7. Use long extension from above, loosen 2
screws securing engine mounting to rear
cross-member and remove screws.
8. Remove engine mounting.
ENGINE - 'KV6'
46 REPAIRS
Refit
1. Position mounting on rear cross-member, with
location peg to the rear, fit LH screw and then
RH screw from above and tighten to 45 Nm.
2. Engage engine mounting and fit mounting
bracket, tighten bolts to 85 Nm.
3. Remove jack support from gearbox.
4. Fit locknut securing mounting to bracket,
tighten to 85 Nm.
5. Remove stand(s) and lower vehicle.
6. Connect battery earth lead.
ENGINE STEADY BAR - FRONT
Service repair no - 12.45.21
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove bolt securing steady bar to body
bracket and collect special nut.
4. Remove bolt securing steady bar to engine
bracket.
5. Remove steady bar from brackets.
Refit
1. Fit steady bar to brackets, cut out facing
downwards.
2. Fit bolt securing steady bar to engine bracket,
finger tight.
3. Fit bolt securing steady bar to body bracket,
locate nut fork in bracket peg, finger tight.
4. Tighten bolts to 85 Nm.
ENGINE - 'KV6'
REPAIRS 47
ENGINE STEADY BAR - REAR
Service repair no - 12.45.22
Remove
1. Disconnect battery earth lead.
2. Remove bolt securing steady bar to body
bracket, use 300 mm extension and universal
joint.
3. Remove bolt securing steady bar to engine
bracket and collect special nut.
4. Remove steady bar from brackets.
Refit
1. Fit steady bar to brackets, cut out facing
downwards.
2. Fit bolt securing steady bar to body bracket,
finger tight.
3. Fit bolt securing stead bar to engine bracket,
locate fork of special nut in bracket peg.
4. Tighten bolts to 85 Nm.
FLYWHEEL
Service repair no - 12.53.07
Remove
1. Remove clutch assembly,
2. Leave flywheel locking tool 18G 1746 in place.
3. Disconnect multiplug from crankshaft position
sensor.
4. Remove bolt securing crankshaft position
sensor to flywheel housing.
5. Remove crankshaft position sensor.
6. Remove and discard 6 bolts securing flywheel
to crankshaft.
7. Remove flywheel from crankshaft.
ENGINE - 'KV6'
48 REPAIRS
Refit
1. Clean bolt holes in crankshaft using an old
flywheel bolt with two saw cuts at an angle of
45to the bolt shank.
2. Clean flywheel and mating face of crankshaft.
3. Fit flywheel to crankshaft.
4. Fit NEW bolts securing flywheel to crankshaft
and tighten progressively in sequence shown
to 100 Nm.
5. Clean crankshaft position sensor and mating
face of flywheel housing.
6. Fit crankshaft position sensor, fit bolt and
tighten to 8 Nm.
7. Connect multiplug to crankshaft position
sensor.
8. Fit clutch assembly,
CONVERTER DRIVE PLATE
Service repair no - 12.53.13
Remove
1. Remove automatic gearbox.
2. Fit flywheel locking tool 18G 1746.
3. Remove and discard 6 bolts securing drive
plate to crankshaft.
4. Remove drive plate from crankshaft.
ENGINE - 'KV6'
REPAIRS 49
Refit
1. Clean bolt holes in crankshaft using an old
drive plate bolt with two saw cuts at an angle of
45to the bolt shank.
2. Clean drive plate and mating face of
crankshaft.
3. Fit drive plate to crankshaft.
4. Fit NEW bolts securing drive plate to
crankshaft and tighten progressively in
sequence shown to 100 Nm. Remove tool 18G
1746.
5. Fit automatic gearbox.
FLYWHEEL STARTER RING GEAR
Service repair no - 12.53.19
Remove
1. Remove flywheel.
2. Apply a cold chisel in root of one of ring gear
teeth, strike chisel with hammer to break ring
gear.
3. Remove starter ring gear.
Refit
1. Clean flywheel and starter ring gear.
2. Heat new starter ring gear evenly to 350C,
indicated when the ring is a light blue colour.
3. Locate ring gear on flywheel and press ring
gear hard against flange on flywheel.
4. Ensure ring gear is correctly seated around the
complete circumference of flywheel and allow
to cool.
5. Fit flywheel.
ENGINE - 'KV6'
50 REPAIRS
OIL FILTER
Service repair no - 12.60.04
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Clean area around filter head and place a
container beneath engine.
3. Using a strap wrench, remove and discard
filter.
Refit
1. Clean mating face of filter head.
2. Lubricate sealing ring of new filter with clean
engine oil.
3. Fit new filter and tighten by hand until it seats
then tighten a further half turn.
4. Top up engine with oil to correct specification
until level is correct.
5. Start and run engine and check for leaks.
6. Stop engine, wait a few minutes, then check oil
level. Top up if necessary.
7. Remove stand(s) and lower vehicle.
OIL PUMP GASKET
Service repair no - 12.60.25
Remove
1. Remove camshaft timing belt.
2. Remove engine oil dipstick.
3. Position container under sump.
4. Remove drain plug from sump and drain
engine oil. Remove sealing washer from drain
plug and discard.
5. Clean drain plug and fit new sealing washer.
6. Fit drain plug and tighten to 28 Nm.
7. Remove 2 nuts securing dipstick tube to sump.
8. Remove dipstick tube.
9. Remove dipstick tube gasket.
10. Remove crankshaft gear.
11. Disconnect multiplugs from oil pressure switch
and oil temperature sensor.
12. Remove 14 bolts securing oil pump.
13. Remove oil pump.
14. Remove oil pump gasket.
ENGINE - 'KV6'
REPAIRS 51
Refit
1. Clean oil pump mating faces and fit new
gasket.
2. Clean oil pump bolts and apply Loctite 242 to
first 3 threads.
3. Fit oil seal guide from seal kit, over end of
crankshaft.
4. Fit oil pump, fit bolts and tighten progressively
in sequence shown to 9 Nm.
5. Connect multiplugs to oil pressure switch and
oil temperature sensor. Clean crankshaft gear
and crankshaft.
6. Fit crankshaft gear.
7. Clean dipstick tube flange mating faces and fit
new gasket.
8. Fit dipstick tube, fit nuts securing dipstick tube
to sump and tighten to 9 Nm.
9. Fit dipstick.
10. Fit camshaft timing belt.
11. Fill engine with correct quantity and grade of
oil.
ENGINE SUMP GASKET
Service repair no - 12.60.38
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove engine oil dipstick.
4. Drain engine oil.
5. Remove 8 bolts securing centre beam to front
and rear cross-members.
6. Remove centre beam.
ENGINE - 'KV6'
52 REPAIRS
7. Turn steering onto RH lock.
8. Remove 3 screws securing RH splash shield to
inner wing and collect spacer from forward
screw.
9. Remove splash shield.
10. Remove 2 nuts securing dipstick tube to sump
and release flange from sump.
11. Loosen 2 nuts securing bracket to exhaust
front pipe.
12. Remove 2 bolts and remove exhaust front pipe
support bracket.
13. Remove 10 bolts securing sump to crankcase
extension, note position of 4 long bolts.
14. Release sump from crankcase extension, use
mallet at front and lever under front housing at
the rear.
15. Remove sump.
ENGINE - 'KV6'
REPAIRS 53
Refit
1. Clean sealing surfaces on sump and
crankcase extension, use foam action gasket
remover and a plastic scraper - DO NOT USE
A METAL SCRAPER ON SEALlNG
SURFACES
2. Apply a 2 mm bead of Hylogrip 2000 sealant
along centre of sump flange and use a roller to
spread sealant across flange.
3. Fit NEW gasket to dipstick flange.
4. Position sump and engage dipstick flange, fit
bolts and tighten progressively in sequence
shown to 25 Nm.
5. Fit nuts to dipstick flange and tighten to 9 Nm.
6. Fit support bracket to exhaust front pipe and
tighten bolts and nuts to 25 Nm.
7. Fit splash shield to inner wing, fit spacer to
forward screw, fit and tighten screws to 9 Nm.
8. Fit centre beam, tighten bolts to 60 Nm.
9. Remove stand(s) and lower vehicle.
10. Connect battery earth lead.
11. lnsert dipstick.
12. Fill engine with correct grade and quantity of
oil.
OIL PRESSURE SWITCH
Service repair no - 12.60.50
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Turn wheel onto RH lock
4. Remove screws securing RH splash shield to
inner wing and collect spacer from forward
screw.
5. Remove splash shield.
6. Position container below engine oil filter to
collect oil spillage.
ENGINE - 'KV6'
54 REPAIRS
7. Disconnect multiplug from oil pressure switch.
8. Remove oil pressure switch.
Refit
1. Clean oil pressure switch threads.
2. Fit oil pressure switch and tighten to 14 Nm.
3. Connect multiplug to oil pressure switch.
4. Fit splash shield to inner wing, fit spacer to
forward screw and tighten screws to 9 Nm.
5. Remove stand(s) and lower vehicle.
6. Top-up engine oil.
7. Connect battery earth lead.
OIL PRESSURE RELIEF VALVE
Service repair no - 12.60.56
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove RH front road wheel.
3. Remove 3 screws securing RH splash shield to
inner wing and collect spacer from forward
screw.
4. Remove splash shield.
ENGINE - 'KV6'
REPAIRS 55
5. Remove plug nut.
6. Remove spring and valve.
Refit
1. Clean valve, spring and nut.
2. Clean valve seating inside oil pump.
3. Lubricate valve and seating with clean engine
oil.
4. Fit valve and spring to pump.
5. Apply Loctite 542 sealant to nut thread.
6. Fit plug nut and tighten to 25 Nm.
7. Fit splash shield to inner wing, fit spacer to
forward screw and tighten screws to 9 Nm.
8. Fit road wheel(s) and tighten nuts to correct
torque.
9. Remove stand(s) and lower vehicle.
10. Top-up engine oil.
OIL TEMPERATURE SENSOR
Service repair no - 12.60.65
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Turn wheel onto RH lock
4. Remove 3 bolts securing RH splash shield to
inner wing and collect spacer from forward bolt
5. Remove splash shield.
6. Position container below engine oil filter to
collect spillage.
ENGINE - 'KV6'
56 REPAIRS
7. Disconnect multiplug from oil temperature
sensor.
8. Remove sensor and discard sealing washer.
Refit
1. Clean oil temperature sensor threads.
2. Fit new sealing washer, fit sensor and tighten
to 14 Nm.
3. Connect multiplug to sensor.
4. Fit splash shield to inner wing, fit spacer to
forward bolt and tighten to 9 Nm.
5. Remove stand(s) and lower vehicle.
6. Top-up engine oil,
7. Connect battery earth lead.
CAMSHAFT TIMING BELT
Service repair no - 12.65.18
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove RH road wheel.
4. Remove 3 bolts securing RH under wing
splash shield. Collect spacer and remove
shield.
5. Remove oil filter.
ENGINE - 'KV6'
REPAIRS 57
6. Remove 2 bolts securing spark plug cover.
7. Remove cover.
8. Remove inlet manifold chamber.
9. Remove bolt securing steady bar to body
bracket.
10. Remove bolt securing steady bar to engine
bracket and collect special nut.
11. Remove steady bar from brackets.
12. Remove LH rear timing belt cover.
13. Set engine in the 'safe' position by rotating
crankshaft in a clockwise direction until rear
camshaft gear hubs on LH bank of cylinders
are positioned as shown, and inserting tool
18G 1746 through hole, located in lower
crankcase under LH bank of cylinders, to lock
crankshaft.
14. Remove LH front timing belt cover.
15. Remove alternator.
16. Remove 3 bolts securing PAS pump and move
pump aside.
ENGINE - 'KV6'
58 REPAIRS
17. Remove spacer from RH engine mounting
bracket.
NOTE: DoweI Iocated.
18. Remove 3 bolts securing timing belt RH front
cover.
19. Remove RH front cover.
20. Remove 5 bolts securing alternator/PAS pump
mounting bracket.
21. Remove mounting bracket and engine lifting
bracket.
22. Remove crankshaft pulley bolt.
23. Remove crankshaft pulley.
24. Remove 3 bolts securing camshaft timing belt
lower cover and remove cover.
25. Remove transmission fluid
dipstick to prevent it being damaged on ABS
modulator when engine is raised.
26. Remove 2 blanking plugs from engine
mounting bracket.
27. Remove 2 bolts securing ancillary drive belt
tensioner and remove tensioner.
28. Remove 4 and loosen 2 bolts securing engine
mounting bracket to engine block.
29. Remove Allen bolt securing engine mounting
bracket to engine block.
30. Raise engine, manoeuvre and lower mounting
bracket. Remove lower bolt.
NOTE: Access for boIt removaI is gained
from under wing. Adjacent boIt remains
captive untiI engine mounting bracket is
removed.
31. Release and remove engine mounting bracket.
32. Remove bolt securing harness clip to oil pump
housing.
ENGINE - 'KV6'
REPAIRS 59
33. Relieve pressure from camshaft timing belt
tensioner using an Allen key fitted to tensioner
pulley and remove 2 bolts securing tensioner.
CAUTION: DO NOT Ioosen AIIen screw
securing tensioner puIIey.
34. Remove tensioner.
35. lf timing belt is to be refitted, mark belt direction
of rotation.
36. Remove timing belt.
CAUTION: Ease timing beIt off gears using
fingers onIy. MetaI Ievers may damage the
beIt and gears.
CAUTION: DO NOT rotate crankshaft with
timing beIt removed and cyIinder heads
fitted.
CAUTION: AIthough the camshaft timing
beIt has a service Iife of 96,000 miIes,
160,000 km, an existing beIt shouId onIy
be refitted if it has compIeted Iess than 48,000
miIes, 80,000 km.
 DO NOT use a timing beIt which has been
twisted or bent doubIe because reinforcing
fibres may be fractured. Timing beIts must be
stored and handIed with care. AIways store a
timing beIt on its edge with a bend radius
greater than 50 mm.
 DO NOT use an oiI contaminated timing beIt.
The cause of oiI contamination MUST be
rectified.
37. Remove bolt securing dipstick tube bracket to
cylinder head.
38. Remove both exhaust camshaft front oil seals.
39. Fit tools 18G 1747-2 to both front timing gears.
CAUTION: TooIs must be fitted when
Ioosening or tightening gear retaining
boIts, otherwise damage to camshafts
may occur.
40. Remove bolts retaining front timing gears and
discard.
41. Remove tools 18G 1747-2.
42. Remove timing gear and hub assemblies.
ENGINE - 'KV6'
60 REPAIRS REVISED: 09/97
Refit
1. Clean timing gears, hubs and pulleys.
2. Fit hubs to timing gears and fit gears to
camshafts. Fit NEW bolts and tighten
sufficiently to allow gears to rotate without
tipping.
3. Position timing belt to gears.
CAUTION: If originaI beIt is to be refitted,
ensure direction of rotation mark is facing
correct way.
4. Fit tools 18G 1747-2 to both front timing gears.
5. Rotate both front timing gears fully clockwise
as viewed from front of engine.
6. Using fingers only, fit timing belt to gears,
starting at the crankshaft gear and working in
an anti-clockwise direction, keeping the run as
taut as possible and turning the camshaft
gears only a minimum amount anti-clockwise
to fit belt.
NOTE: To prevent timing beIt from
disengaging from crankshaft gear when
fitting, fit a suitabIe wedge between beIt
and oiI pump beIt guard.
7. Using a vice, slowly compress tensioner
plunger and fit a suitable pin, 1.5 mm in
diameter, to retain plunger.
8. Clean tensioner bolts and apply Loctite 242 to
first 3 threads.
9. Hold tensioner pulley against belt using an
Allen key.
10. Position tensioner, fit bolts and tighten to 25
Nm.
11. Release tensioner pulley and remove pin from
tensioner.
12. Position harness clip to oil pump housing, fit
bolt and tighten to 9 Nm.
13. Tighten front timing gear bolts to 27 Nm.
Tighten bolts a further 90.
14. Remove tools 18G 1747-2.
15. Remove wedge from between timing belt and
oil pump belt guard.
16. Ensuring bolt that remains captive is fitted to
mounting bracket, manoeuvre bracket into
position.
17. Fit RH lower bolt and align bracket to engine
taking care not to displace timing cover
backplate seals.
18. Fit remaining bolts but DO NOT tighten bolts at
this stage.
19. Position alternator/PAS pump mounting
bracket and engine lifting bracket. fit bolts and
tighten to 45 Nm.
ENGINE - 'KV6'
REPAIRS 61
20. Tighten engine mounting bracket bolts in the
sequence shown to the following torques:
Bolt 1, 32 Nm.
Bolt 5, 45 Nm.
Bolts 2, 3, 4, 6 and 7, 85 Nm.
21. Position ancillary belt tensioner, fit bolts and
tighten to 25 Nm.
22. Fit blanking plugs to engine mounting bracket.
23. Clean and refit transmission
fluid dipstick.
24. Clean lower timing belt cover.
25. Fit cover, fit bolts and tighten to 9 Nm.
26. Clean crankshaft pulley.
27. Fit crankshaft pulley to crankshaft gear.
CAUTION: Ensure indent on puIIey Iocates
over Iug on gear.
28. Fit crankshaft pulley bolt and washer, tighten
bolt to 160 Nm.
29. Remove tool 18G 1746.
30. Position PAS pump to bracket, fit bolts and
tighten to 25 Nm.
31. Clean exhaust camshaft front seal locations
and fit new seals.
CAUTION: SeaIing edge of seaI and
mating face must be cIean and dry.
32. Align dip stick tube bracket to cylinder head, fit
bolt and tighten to 9 Nm.
33. Fit RH front timing cover taking care not to
displace seal.
34. Fit 3 bolts securing cover and tighten to 4 Nm.
35. Clean spacer and mating face on engine
bracket.
36. Fit spacer to mounting bracket.
37. Fit alternator.
38. Fit LH front timing belt cover.
39. Fit rear steady bar to brackets, cut out facing
downwards.
40. Fit bolt securing steady bar to body bracket,
finger tight.
41. Fit bolt securing steady bar to engine bracket,
locate fork of special nut in bracket peg.
42. Tighten bolts to 85 Nm.
43. Fit inlet manifold chamber.
44. Fit LH rear timing belt cover.
45. Fit spark plug cover, fit bolts and tighten to 4
Nm.
46. Fit oil filter.
47. Fit splash shield, align PAS hose clip, fit spacer
to front bolt and tighten bolts.
48. Fit road wheel(s) and tighten nuts to correct
torque.
49. Remove stand(s) and lower vehicle.
ENGINE - 'KV6'
62 REPAIRS REVISED: 09/97
CAMSHAFT TIMING BELT - AIR CONDITIONING
Service repair no - 12.65.18/20
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove RH road wheel.
4. Remove 3 bolts securing RH under wing
splash shield. Collect spacer and remove
shield.
5. Remove oil filter.
6. Remove underbelly panel.
7. Remove 2 bolts securing spark plug cover.
8. Remove cover.
9. Remove inlet manifold chamber.
10. Remove bolt securing rear steady bar to body
bracket.
11. Remove bolt securing steady bar to engine
bracket and collect special nut.
12. Remove steady bar from brackets.
13. Remove LH rear timing belt cover.
ENGINE - 'KV6'
REPAIRS 63
14. Set engine in the 'safe' position by rotating
crankshaft in a clockwise direction until rear
camshaft gear hubs on LH bank of cylinders
are positioned as shown and inserting tool 18G
1746 through hole, located in lower crankcase
under LH bank of cylinders, to lock crankshaft.
15. Remove LH front timing belt cover.
16. Remove alternator.
17. Remove 3 bolts securing PAS pump and move
pump aside.
ENGINE - 'KV6'
64 REPAIRS
18. Remove spacer from RH engine mounting
bracket.
NOTE: DoweI Iocated.
19. Remove 3 bolts securing timing belt RH front
cover.
20. Remove RH front cover.
21. Remove 5 bolts securing alternator/PAS pump
mounting bracket.
22. Remove mounting bracket and engine lifting
bracket.
23. Remove crankshaft pulley bolt.
24. Remove crankshaft pulley.
25. Remove 3 bolts securing camshaft timing belt
lower cover and remove cover.
26. Remove gearbox fluid dip
stick to prevent it being damaged on ABS
modulator when engine is raised.
27. Remove 2 blanking plugs from engine
mounting bracket.
28. Remove 2 bolts securing ancillary drive belt
tensioner and remove tensioner.
29. Remove 4 bolts securing compressor to
mounting bracket.
30. Release compressor and lay aside.
31. Remove compressor heat shield.
32. Remove 2 bolts securing compressor mounting
bracket to engine mounting bracket
33. Remove 4 and loosen 2 bolts securing engine
mounting bracket to engine block.
34. Remove Allen bolt securing engine mounting
bracket to engine block.
35. Raise engine, manoeuvre and lower mounting
bracket. Remove lower bolt.
NOTE: Access for boIt removaI is gained
from under wing. Adjacent boIt remains
captive untiI engine mounting bracket is
removed.
ENGINE - 'KV6'
REPAIRS 65 REVISED: 09/97
36. Release and remove engine mounting bracket.
37. Remove bolt securing harness clip to oil pump
housing.
38. Relieve pressure from camshaft timing belt
tensioner using an Allen key fitted to tensioner
pulley and remove 2 bolts securing tensioner.
CAUTION: DO NOT Ioosen AIIen screw
securing tensioner puIIey.
39. Remove tensioner.
40. lf timing belt is to be refitted, mark belt direction
of rotation.
41. Remove timing belt.
CAUTION: Ease timing beIt off gears using
fingers onIy. MetaI Ievers may damage the
beIt and gears.
CAUTION: DO NOT rotate crankshaft with
timing beIt removed and cyIinder heads
fitted.
CAUTION: AIthough the camshaft timing
beIt has a service Iife of 96,000 miIes,
160,000 km, an existing beIt shouId onIy
be refitted if it has compIeted Iess than 48,000
miIes, 80,000 km.
 DO NOT use a timing beIt which has been
twisted or bent doubIe because reinforcing
fibres may be fractured. Timing beIts must be
stored and handIed with care. AIways store a
timing beIt on its edge with a bend radius
greater than 50 mm.
 DO NOT use an oiI contaminated timing beIt.
The cause of oiI contamination MUST be
rectified.
42. Remove bolt securing dipstick tube bracket to
cylinder head.
43. Remove both exhaust camshaft front oil seals.
44. Fit tools 18G 1747-2 to both front timing gears
to hold gears.
CAUTION: TooIs must be fitted when
Ioosening or tightening gear retaining
boIts, otherwise damage to camshafts
may occur.
45. Remove bolts retaining front timing gears and
discard.
46. Remove tools 18G 1747-2.
47. Remove timing gear and hub assemblies.
ENGINE - 'KV6'
66 REPAIRS
Refit
1. Clean timing gears, hubs and pulleys.
2. Fit hubs to timing gears and fit gears to
camshafts.
3. Fit NEW bolts and tighten sufficiently to allow
gears to rotate without tipping.
4. Position timing belt to gears.
CAUTION: If originaI beIt is to be refitted,
ensure direction of rotation mark is facing
correct way.
5. Fit tools 18G 1747-2 to both front timing gears.
6. Rotate both front timing gears fully clockwise
as viewed from front of engine.
7. Using fingers only, fit timing belt to gears,
starting at the crankshaft gear and working in
an anti-clockwise direction, keeping the run as
taut as possible and turning the camshaft
gears only a minimum amount anti-clockwise
to fit belt.
NOTE: To prevent timing beIt from
disengaging from crankshaft gear when
fitting, fit a suitabIe wedge between beIt
and oiI pump beIt guard.
8. Using a vice, slowly compress tensioner
plunger and fit a suitable pin, 1.5 mm in
diameter, to retain plunger.
9. Clean tensioner bolts and apply Loctite 242 to
first 3 threads.
10. Hold tensioner pulley against belt using an
Allen key.
11. Position tensioner, fit bolts and tighten to 25
Nm.
12. Release tensioner pulley and remove pin from
tensioner.
13. Position harness clip to oil pump housing, fit
bolt and tighten to 9 Nm.
14. Tighten front timing gear bolts to 28 Nm.
Tighten bolts a further 90.
15. Remove tools 18G 1747.
16. Remove wedge from between timing belt and
oil pump belt guard.
17. Ensuring bolt that remains captive is fitted to
mounting bracket, manoeuvre bracket into
position.
18. Fit RH lower bolt and align bracket to engine
taking care not to displace timing cover
backplate seals.
19. Fit remaining bolts but DO NOT tighten bolts at
this stage.
20. Position alternator/PAS pump mounting
bracket and engine lifting bracket. fit bolts and
tighten to 45 Nm.
ENGINE - 'KV6'
REPAIRS 67
21. Tighten engine mounting bracket bolts in the
sequence shown to the following torques:
Bolt 1 32 Nm.
Bolt 5 45 Nm.
Bolts 2, 3, 4, 6 and 7 85 Nm.
22. Fit bolts securing compressor mounting
bracket to engine mounting bracket and tighten
to 45 Nm.
23. Align compressor to bracket, position
heatshield, fit bolts and tighten to 25 Nm.
24. Position ancillary belt tensioner, fit bolts and
tighten to 25 Nm.
25. Fit blanking plugs to engine mounting bracket.
26. Clean and refit gearbox
fluid dip stick.
27. Clean lower timing belt cover.
28. Fit cover, fit bolts and tighten to 9 Nm.
29. Clean crankshaft pulley.
30. Fit crankshaft pulley to crankshaft gear.
CAUTION: Ensure indent on puIIey Iocates
over Iug on gear.
31. Fit crankshaft pulley bolt and washer, tighten
bolt to 160 Nm.
32. Remove tool 18G 1746.
33. Position PAS pump to bracket, fit bolts and
tighten to 25 Nm.
34. Clean exhaust camshaft front seal locations
and fit new seals.
CAUTION: SeaIing edge of seaI and
mating face must be cIean and dry.
35. Align dip stick tube bracket to cylinder head, fit
bolt and tighten to 9 Nm.
36. Fit RH front timing cover taking care not to
displace seal.
37. Fit 3 bolts securing cover and tighten to 4 Nm.
38. Clean spacer and mating face on engine
bracket.
39. Fit spacer to mounting bracket.
40. Fit alternator.
41. Fit rear steady bar to brackets, cut-out facing
downwards.
42. Fit bolt securing steady bar to body bracket,
finger tight.
43. Fit bolt securing steady bar to engine bracket,
locate fork of special nut in bracket peg.
44. Tighten both bolts to 85 Nm.
45. Fit inlet manifold chamber.
46. Fit LH rear timing belt cover.
47. Fit spark plug cover, fit bolts and tighten to 4
Nm.
48. Fit oil filter.
49. Fit splash shield, align PAS hose clip, fit spacer
to front bolt and tighten bolts.
50. Fit underbelly panel.
51. Fit road wheel(s) and tighten nuts to correct
torque.
52. Remove stand(s) and lower vehicle.
ENGINE - 'KV6'
68 REPAIRS
TIMING BELT COVER - FRONT RH
Service repair no - 12.65.39
Remove
1. Disconnect battery earth lead.
2. Remove engine acoustic cover,
3. Position trolley jack under sump to support
engine.
CAUTION: Use a bIock of wood or hard
rubber pad to protect sump.
4. Loosen through bolt securing RH engine
mounting bracket to body.
5. Remove 2 bolts securing engine mounting
bracket to engine.
6. Swivel mounting bracket away from engine and
tighten through bolt to hold bracket clear of
engine.
7. Raise engine.
8. Release and remove spacer from engine
bracket.
NOTE: DoweI Iocated.
9. Remove 3 bolts securing cover.
10. Remove cover.
11. Remove seal from cover.
Refit
1. Fit seal to cover.
2. Fit cover taking care not to displace seal.
3. Fit bolts securing cover and tighten to 4 Nm.
4. Clean spacer and mating face on engine
bracket.
5. Fit spacer.
6. Loosen engine mounting bracket through bolt
and swivel bracket over.
7. Lower engine and align engine mounting
bracket.
8. Fit engine mounting bracket bolts and tighten
to 75 Nm.
9. Tighten through bolt to 45 Nm.
10. Fit engine acoustic cover,
11. Connect battery earth lead.
ENGINE - 'KV6'
REPAIRS 69
TIMING BELT COVER - FRONT LH
Service repair no - 12.65.41
Remove
1. Disconnect battery earth lead.
2. Remove engine acoustic cover,
3. Loosen 3 bolts securing PAS pump pulley.
4. Using a 25 mm spanner, raise ancillary drive
belt tensioner and release drive belt from
alternator and PAS pump pulleys.
5. Remove bolts securing PAS pump pulley.
6. Remove pulley.
7. Remove bolt securing PAS pipe clip to engine
bracket.
8. Remove 3 bolts securing timing belt cover.
9. Ease PAS pipe away from engine.
10. Release and remove cover.
11. Remove seal from cover.
ENGINE - 'KV6'
70 REPAIRS
Refit
1. Fit seal to cover.
2. Fit cover taking care not to displace seal.
3. Fit bolts securing cover and tighten to 4 Nm.
4. Align PAS pipe clip to engine bracket. fit and
tighten bolt.
5. Fit PAS pump pulley and fit bolts.
6. Raise belt tensioner and connect drive belt to
alternator and PAS pump pulleys.
CAUTION: Ensure beIt is correctIy Iocated
in puIIey grooves.
7. Tighten PAS pulley bolts to 9 Nm.
8. Fit engine acoustic cover,
9. Connect battery earth lead.
TIMING BELT COVER - FRONT LH - AIR
CONDITIONING
Service repair no - 12.65.41/20
Remove
1. Remove ancillary drive belt.
2. Remove bolts securing PAS pump pulley.
3. Remove pulley.
4. Remove bolt securing PAS pipe clip to engine
bracket.
5. Remove 3 bolts securing timing belt cover.
6. Ease PAS pipe away from engine.
7. Release and remove cover.
8. Remove seal from cover.
ENGINE - 'KV6'
REPAIRS 71
Refit
1. Fit seal to cover.
2. Fit cover taking care not to displace seal.
3. Fit bolts securing cover and tighten to 4 Nm.
4. Align PAS pipe clip to engine bracket. fit and
tighten bolt.
5. Fit PAS pump pulley and tighten bolts to 9 Nm.
6. Fit ancillary drive belt.
7. Connect battery earth lead.
TIMING BELT COVER - REAR LH
Service repair no - 12.65.46
Remove
1. Disconnect battery earth lead.
2. Release top hose from support clip.
3. Remove 3 screws securing cover.
4. Remove LH rear timing belt cover.
Refit
1. Fit rear cover to back cover.
2. Fit and and tighten screws to 4 Nm.
3. Fit top hose into support clip.
4. Connect battery earth lead.
ENGINE - 'KV6'
72 REPAIRS
TIMING BELT COVER - REAR RH
Service repair no - 12.65.47
Remove
1. Disconnect battery earth lead.
2. Remove inlet manifold chamber.
3. Remove rear steady bar from engine.
4. Remove bolt securing coolant pipe bracket to
steady bar mounting bracket. Position coolant
pipe aside.
5. Release harness clip from steady bar bracket.
6. Remove 2 bolts securing steady bar bracket to
bell housing.
7. Manoeuvre steady bar bracket(s) from housing
and remove.
NOTE: On modeIs fitted with automatic
gearbox the steady bar bracket is in two
pieces.
8. Remove 3 screws securing cover.
9. Remove RH rear timing belt cover.
Refit
1. Fit RH rear timing belt cover to back cover and
tighten screws to 4 Nm.
2. Fit steady bar bracket(s) and tighten bolts to 85
Nm.
3. Fit harness clip to steady bar bracket.
4. Position coolant pipe bracket to steady bar and
tighten bolt.
5. Fit rear steady bar to engine.
6. Fit inlet manifold chamber.
7. Connect battery earth lead.
ENGINE - 'KV6'
REPAIRS 73
CAMSHAFT REAR TIMING BELT - LH BANK
Service repair no - 12.65.56
Remove
1. Disconnect battery earth lead.
2. Remove air cleaner.
3. Remove LH rear timing belt cover.
4. Raise front of vehicle.
WARNING: Support on safety stands.
5. Remove RH road wheel.
6. Remove 3 bolts securing RH under wing
splash shield. Collect spacer and remove
splash shield.
7. Rotate crankshaft in a clockwise direction and
fit tool 18G 1747 to LH rear timing gears.
CAUTION: Use hand pressure onIy when
fitting tooI 18G 1747 to timing gears. TooI
18G 1747 must be fitted when Ioosening
or tightening camshaft gear retaining boIts
otherwise damage to camshafts may occur.
ENGINE - 'KV6'
74 REPAIRS
8. Remove 2 bolts securing rear timing gears to
camshafts.
9. Remove rear timing gears and timing belt
assembly.
10. Remove tool 18G 1747 from timing gears.
11. lf timing belt is to be refitted, mark belt direction
of rotation.
12. Remove timing belt from gears.
CAUTION: DO NOT rotate crankshaft with
timing beIt removed and cyIinder heads
fitted.
CAUTION: AIthough the camshaft timing
beIt has a service Iife of 96,000 miIes,
160,000 km, an existing beIt shouId onIy
be refitted if it has compIeted Iess than 48,000
miIes, 80,000 km.
 DO NOT use a timing beIt which has been
twisted or bent doubIe because reinforcing
fibres may be fractured. Timing beIts must be
stored and handIed with care. AIways store a
timing beIt on its edge with a bend radius
greater than 50 mm.
 DO NOT use an oiI contaminated timing beIt.
The cause of oiI contamination MUST be
rectified.
Refit
1. Clean timing gears, hubs and mating faces on
camshafts. Fit hubs to gears.
2. Place gears on a flat surface with timing belt
guide plates facing up on inlet camshaft gear
and down on exhaust camshaft gear. Ensure
centre hubs are in the position shown and fit
timing belt to gears.
CAUTION: If originaI beIt is to be refitted,
ensure direction of rotation mark is facing
correct way.
3. Fit tool 18G 1747-1 to gears, turn centre screw
to seperate gears sufficiently to fit tool 18G
1747 .
ENGINE - 'KV6'
REPAIRS 75
4. Remove LH exhaust camshaft front oil seal
and discard .
5. Fit tool 18G 1747-4 to front end of LH exhaust
camshaft.
6. Fit alignment pins 18G 1747-5 to rear ends of
camshafts.
7. Position camshaft rear drive gear assembly
and with assistance carefully align exhaust
camshaft to rear drive gear by rotating 18G
1747-4 and fit gear assembly.
CAUTION: When gears are fitted, timing
beIt guide pIate on inIet camshaft drive
gear shouId face outwards.
8. Remove alignment pins 18G 1747-5 from
camshafts.
9. Fit camshaft gear retaining bolts and tighten to
25 Nm plus a further 90.
10. Remove tool 18G 1747 from rear timing gears.
11. Remove tool 18G 1747-1 from gears.
12. Remove tool 18G 1747-4 from exhaust
camshaft.
13. Fit LH rear timing belt cover.
14. Clean exhaust camshaft oil seal recess and fit
new seal.
15. Fit splash shield, fit spacer to front bolt and
tighten bolts.
16. Fit road wheel(s) and tighten nuts to correct
torque.
17. Remove stand(s) and lower vehicle.
18. Fit air cleaner.
19. Connect battery earth lead.
ENGINE - 'KV6'
76 REPAIRS
CAMSHAFT REAR TIMING BELT - RH BANK
Service repair no - 12.65.57
Remove
1. Disconnect battery earth lead.
2. Remove RH rear timing belt cover.
3. Raise front of vehicle.
WARNING: Support on safety stands.
4. Remove RH road wheel.
5. Remove 3 bolts securing RH under wing
splash shield. Collect spacer and remove
splash shield.
6. Rotate crankshaft in a clockwise direction and
fit tool 18G 1747 to RH rear timing gears.
CAUTION: Use hand pressure onIy when
fitting 18G 1747 to timing gears. TooI 18G
1747 must be fitted when Ioosening or
tightening camshaft gear retaining boIts,
otherwise damage to camshafts may occur.
ENGINE - 'KV6'
REPAIRS 77
7. Remove 2 bolts securing rear timing gears to
camshafts.
8. Remove rear timing gears and timing belt
assembly.
9. Remove tool 18G 1747 from timing gears.
10. lf timing belt is to be refitted, mark belt direction
of rotation.
11. Remove timing belt from gears.
CAUTION: DO NOT rotate crankshaft with
timing beIt removed and cyIinder heads
fitted.
CAUTION: AIthough the camshaft timing
beIt has a service Iife of 96,000 miIes,
160,000 km, an existing beIt shouId onIy
be refitted if it has compIeted Iess than 48,000
miIes, 80,000 km.
 DO NOT use a timing beIt which has been
twisted or bent doubIe because reinforcing
fibres may be fractured. Timing beIts must be
stored and handIed with care. AIways store a
timing beIt on its edge with a bend radius
greater than 50 mm.
 DO NOT use an oiI contaminated timing beIt.
The cause of oiI contamination MUST be
rectified.
Refit
1. Clean timing gears, hubs and mating faces on
camshafts. Fit hubs to gears.
2. Place gears on a flat surface with timing belt
guide plates facing up on inlet camshaft gear
and down on exhaust camshaft gear. Ensure
centre hubs are in the position shown and fit
timing belt to gears.
CAUTION: If originaI beIt is to be refitted,
ensure direction of rotation mark is facing
correct way.
3. Fit tool 18G 1747-1 to gears, turn centre screw
to separate gears sufficiently to fit tool 18G
1747 .
ENGINE - 'KV6'
78 REPAIRS
4. Remove and discard RH exhaust camshaft
front oil seal.
5. Fit tool 18G 1747-4 to front end of RH exhaust
camshaft.
6. Fit alignment pins 18G 1747-5 to rear ends of
camshafts.
7. Position camshaft rear drive gear assembly
and with assistance carefully align exhaust
camshaft to rear drive gear by rotating 18G
1747-4 .
CAUTION: When gears are fitted, timing
beIt guide pIate on inIet camshaft drive
gear shouId face outwards.
8. Remove alignment pins 18G 1747-5 from
camshafts.
9. Fit camshaft gear retaining bolts and tighten to
25 Nm plus a further 90.
10. Remove tool 18G 1747 from rear timing gears.
11. Remove tool 18G 1747-1 from gears.
12. Remove tool 18G 1747-4 from exhaust
camshaft.
13. Fit RH rear timing belt cover.
14. Clean exhaust camshaft oil seal recess and fit
new seal.
15. Fit splash shield, fit spacer to front bolt and
tighten bolts.
16. Fit road wheel(s) and tighten nuts to correct
torque.
17. Remove stand(s) and lower vehicle.
18. Connect battery earth lead.