Dismantling
1. Remove and dispose of the timing belt.
KV6 ENGINE - K MODIFICATION, Piston group, Timing belt.
2. Remove the inlet receiver.
MANIFOLDS AND EXHAUST SYSTEM: MOD. K, move. V6, ENGINE OVERHAUL, Intake reservoir seals: vehicles built before May 2003.
3. 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.
4. Release the oxygen sensor harness from the clamp on the cylinder block.
5. In the sequence shown in the figure, unscrew the 4 nuts securing the exhaust manifold to the cylinder head. Remove the exhaust manifold and discard its gasket.
6. Remove the valve cover of the left cylinder head.
KV6 ENGINE - VERSION K, Left cylinder head camshafts, Left cylinder head valve cover gasket: up to May 2003.
7. Loosen the clamp, disconnect the steam outlet hose from the left intake manifold and move the hose aside.
8. Wring out shoulders and take out a ventilation hose from the left inlet collector.
9. Disconnect the right-hand injector harness or from the injector guard (if provided) or from tides on the fuel rail.
10. Turn off 2 bolts of fastening of a protective casing of atomizers (if provided) and the right fuel rail to the right intake manifold and remove the shroud.
11. Turn away 2 bolts of fastening of a fuel stage to the left inlet manifold.
12. 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.
13. In the sequence shown in the figure, loosen and unscrew the 8 cylinder head bolts.
14. Remove the cylinder head.
CAUTION: Place the cylinder head on wooden blocks.
15. Remove and discard the cylinder head gasket.
CAUTION: Do not rotate the crankshaft with the right cylinder head installed (and removed timing belt).
16. 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: 25 Nm
- Stage 3: 25 Nm
- Step 4 - Using an angle torque wrench, tighten the bolts, in the same sequence, 180 degrees.
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. Attach the steam outlet hose of the cooling system to the intake manifold and secure it with a clamp.
19. Attach a ventilation hose to the left intake manifold.
20. Install the ignition coils on the left intake manifold.
21. Install wire "masses", install the harness mounting bolts to the left intake manifold and tighten to 9 Nm.
22. Clean the front timing belt rear cover bolts and apply STC 50552 sealant to the first three threads.
23. Establish a back cover of a belt, screw in bolts and tighten them the moment of 9 Nanometers.
24. Wipe the exhaust manifold and mating surface on the cylinder head.
25. Install a new exhaust manifold gasket. Install the exhaust manifold, fit the nuts and tighten them to 45 Nm in the sequence shown in the figure.
26. Attach the oxygen sensor harness to the clamp on the cylinder block.
27. Connect the oxygen sensor connector and secure it to the bracket.
28. Install a new timing belt.
KV6 ENGINE - K MODIFICATION, Piston group, Timing belt.
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