Dismantling
1. Disconnect "negative" battery terminal.
2. Drain the engine coolant.
COOLING SYSTEM: MOD. K, KV6 engine, ADJUSTMENTS, Coolant drain, system flush and fill.
3. Remove the inlet receiver.
MANIFOLDS AND EXHAUST SYSTEM: MOD. K, move. V6, REPAIRS, Intake reservoir seals: vehicles manufactured before May 2003.
4. Remove the left exhaust manifold gasket.
MANIFOLDS AND EXHAUST SYSTEM: MOD. K, move. V6, REPAIRS, LH exhaust manifold gasket: except for North American market.
MANIFOLDS AND EXHAUST SYSTEM: MOD. K, move. V6, REPAIR WORK, Gasket (gaskets) left exhaust manifold: North American market countries.
5. Remove the timing belt.
KV6 ENGINE - MODIFICATION K, Left cylinder head camshafts, Timing belt.
6. Turn away 4 bolts of fastening of a back cover of a forward timing belt to the left head of cylinders and remove a cover.
7. Remove the valve cover gasket of the left cylinder head.
KV6 ENGINE - VERSION K, Left cylinder head camshafts, Left cylinder head valve cover gasket: up to May 2003.
8. Turn away 3 nuts and 3 bolts of fastening of coils of ignition to the left inlet manifold and disconnect a wire "masses" coils, if provided.
9. Remove ignition coils and take them aside.
10. Loosen the clamp, disconnect the steam outlet hose from the intake manifold and move the hose aside.
11. Wring out shoulders and take out a ventilation hose from the left inlet collector.
12. Disconnect the right-hand injector harness or from the injector guard (if provided) or from tides on the fuel rail.
13. Turn off 2 bolts of fastening of a protective casing of atomizers (if provided) and fuel rail to the right intake manifold and remove the shroud.
14. Turn away 2 bolts of fastening of a fuel rail to the left inlet manifold.
15. Release the injectors from the manifolds and carefully lay the injector rail aside.
CAUTION: Always plug fittings and openings to keep dirt out of the system.
16. In the sequence shown in the figure, loosen and unscrew the 8 cylinder head bolts.
17. Using a partner, remove the cylinder head.
CAUTION: Place the cylinder head on wooden blocks.
18. Remove and dispose of the cylinder head gasket.
Do not rotate the crankshaft with the cylinder head installed (and removed timing belt).
19. Install the LRT-12-144 mounts on the cylinder liners and tighten them with the cylinder head mounting bolts.
ATTENTION: The base of the cylinder liners must not protrude above the cylinder face.
Installation
1. Wipe the bottom plane of a head of cylinders.
CAUTION: Use special cleaning fluid and a plastic scraper.
2. Turn out bolts from fastenings of sleeves of cylinders LRT-12-144 and remove fastenings.
CAUTION: Do not rotate the crankshaft.
3. Clear the top plane of the block of cylinders and apertures under adjusting pins.
4. Wash the cylinder head bolts and wipe them dry.
5. Lightly lubricate the threaded portion and headrests of the bolts with clean engine oil.
6. Check that the protrusion of the pins above the plane of the block is within 10-11 mm. Replace pins if protrusion does not match above values.
7. Fit a new cylinder head gasket to the cylinder block with the 'TOP' mark facing up.
8. With the help of a partner, place the head on the cylinder block and carefully install the left intake manifold on the right one.
9. Carefully insert the cylinder head bolts, DO NOT RELEASE THE BOLTS SO THEY FALL INTO THE SOCKETS. Tighten the bolts by hand.
10. Tighten the cylinder head bolts in the sequence shown in the figure.
- Stage 1: 25 Nm
- Stage 2: in the same sequence, tighten 25 Nm
- Stage 3: in the same sequence, tighten 25 Nm
- Step 4 - Using an angle torque wrench, tighten the bolts, in the same sequence, 180°
11. Install the left cylinder head valve cover gasket.
KV6 ENGINE - VERSION K, Left cylinder head camshafts, Left cylinder head valve cover gasket: up to May 2003.
12. Remove O-rings from injectors and discard.
13. Wipe the nozzles and their nests in the fuel rail.
14. Lubricate new O-rings with castor oil and install them on the injectors.
15. Install the fuel rail assembly and secure the injectors to the intake manifolds.
16. Install injector protection on the right fuel rail (if provided) and secure the injector harness to the clips on the protective cover.
17. Screw in the bolts securing the fuel rail to the intake manifold and tighten them. Tightening torque 9 Nm.
18. Install the camshaft position sensor mounting bracket, screw in the bolt and tighten to 9 Nm.
19. Connect the camshaft position sensor connector and secure it to the bracket.
20. Attach a ventilation hose to the left intake manifold.
21. Attach the steam outlet hose of the cooling system to the intake manifold and secure it with a clamp.
22. Install the ignition coils on the left intake manifold.
23. Install the wire "masses", install the harness mounting bolts to the left intake manifold and tighten to 9 Nm.
24. Install the high voltage wire bracket, screw in and tighten the special bolt.
25. Connect the high voltage wires to the spark plugs and secure the wires to the bracket.
26. Clean the timing belt rear cover bolts and apply STC 50552 sealant to the first three threads.
27. Establish a back cover of a belt, screw in bolts and tighten them the moment of 9 Nanometers.
28. Install the timing belt.
KV6 ENGINE - MODIFICATION K, Left cylinder head camshafts, Timing belt.
29. Install the left exhaust manifold gasket.
MANIFOLDS AND EXHAUST SYSTEM: MOD. K, move. V6, REPAIRS, LH exhaust manifold gasket: except for North American market.
MANIFOLDS AND EXHAUST SYSTEM: MOD. K, move. V6, REPAIR WORK, Gasket (gaskets) left exhaust manifold: North American market countries.
30. Install the inlet receiver.
MANIFOLDS AND EXHAUST SYSTEM: MOD. K, move. V6, REPAIRS, Intake reservoir seals: vehicles manufactured before May 2003.
31. Fill the cooling system with coolant.
COOLING SYSTEM: MOD. K, KV6 engine, ADJUSTMENTS, Coolant drain, system flush and fill.
32. Check the oil level and top up if necessary.
MAINTENANCE, MAINTENANCE, Engine oil and oil filter - KV6.
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