18.20.02 Spark plugs - from 03MY

Remove

1. Disconnect battery earth lead.2. Remove the engine acoustic cover.

*** 12.30.50 Cover - engine acoustic ***

3. Release locking clips and disconnect multiplugs from plug top coils.4. Remove 6 bolts securing plug top coils to cylinder heads.5. Pull to release and remove 6 plug top coils from cylinder heads.6. Using a 16 mm plug socket, remove spark plugs from cylinder heads.

Refit

1. Check and if necessary set spark plug gap.*** Engine - KV6 Petrol ***

2. Fit spark plugs and tighten to 25 Nm (18 lbf.ft).3. Apply a rubber lubricant to plug top coil lower seals and fit coils fully into cylinder

heads.4. Fit bolts securing plug top coils and tighten to 10 Nm (7 lbf.ft).5. Connect and secure multiplugs to plug top coils.

6. Fit the engine acoustic cover.*** 12.30.50 Cover - engine acoustic ***

7. Connect battery earth lead.

18.20.46 Coil - each - LH bank - from 03MY

Remove

1. Disconnect battery earth lead.2. Remove the engine acoustic cover.

*** 12.30.50 Cover - engine acoustic ***

3. Withdraw multiplug lock, release and disconnect plug top coil multiplug.4. Remove bolt securing plug top coil to camshaft rocker cover.5. Remove plug top coil from camshaft rocker cover.

Refit

1. Apply a rubber lubricant to plug top coil, lower seal.2. Fit plug top coil to camshaft rocker cover, fit bolt and tighten to 5 Nm (3.7 lbf.ft).3. Fit and secure plug top coil multiplug.4. Fit the engine acoustic cover.

*** 12.30.50 Cover - engine acoustic ***5. Connect the battery earth lead.6. If a new plug top coil has been fitted, reset ECM adaptions using T4.

18.20.47 Coil - each - RH bank - from 03MY

Remove

1. Disconnect battery earth lead.2. Remove the engine acoustic cover.

*** 12.30.50 Cover - engine acoustic ***

3. Withdraw multiplug lock, release and disconnect plug top coil multiplug.4. Remove bolt securing plug top coil to camshaft rocker cover.5. Remove plug top coil from camshaft rocker cover.

Refit

1. Apply a rubber lubricant to plug top coil, lower seal.2. Fit plug top coil to camshaft rocker cover, fit bolt and tighten to 5 Nm (3.7 lbf.ft).3. Fit and secure plug top coil multiplug.

4. Fit the engine acoustic cover.*** 12.30.50 Cover - engine acoustic ***

5. Connect the battery earth lead.6. If a new plug top coil has been fitted, reset ECM adaptions using T4.

18.30.01 Engine control module (ECM) - Non NAS

Remove

1. Disconnect battery earth lead.

2. Remove 5 Allen screws securing cover to 'E' box and remove cover.

3. Release latch and disconnect multiplug from ECM.

4. Remove ECM from 'E' box.

Refit

1. Fit ECM into 'E' box.2. Position and connect multiplug to ECM and secure latch.3. Fit 'E' box cover and tighten Allen screws to 2 Nm (1.5 lbf.ft).4. Connect battery earth lead.5. If a new ECM has been fitted, reset adaptions using T4.

18.30.03 Engine control module (ECM) - fuel - NAS

Remove

1. Disconnect battery earth lead.

2. Remove 5 Allen screws and 'E' box cover.

3. Disconnect 5 multiplugs from engine ECM.

4. Release 2 clips and remove ECM.

Refit

1. Fit ECM and connect multiplugs.2. Fit 'E' box cover and tighten Allen screws to 2 Nm (1.5 lbf.ft).3. Connect battery earth lead.4. Initiate ECM using T4.

CAUTION: The ECM can only be re-programmed a maximum of 20 times.

18.30.05 Idle Air Control Valve (IACV)

Remove

1. Disconnect battery earth lead.2. Remove engine acoustic cover.

*** 12.30.50 Cover - engine acoustic ***

3. Disconnect multiplug from IACV.4. Depress locking collar and release vacuum hose from IACV housing.

5. Remove 2 Allen bolts securing IACV to throttle body.6. Remove IACV and discard gasket.

Refit

1. Clean mating faces of IACV and throttle body.2. Fit new gasket to IACV.3. Position IACV to throttle body, fit and tighten Allen bolts.4. Connect vacuum hose to IACV.5. Connect multiplug to IACV.

6. Fit engine acoustic cover.*** 12.30.50 Cover - engine acoustic ***

7. Connect battery earth lead.

18.30.09 Sensor - intake air temperature (IAT) - NAS

Remove

1. Disconnect multiplug from IAT sensor.2. Release clip and remove IAT sensor. Discard seal.

Refit

1. Clean IAT sensor and mating face.2. Fit new seal to sensor.3. Fit IAT sensor and connect multiplug.

18.30.10 Sensor - engine coolant temperature (ECT)

Remove

1. Disconnect battery earth lead.2. Remove thermostat.

*** 26.45.01 Thermostat ***

3. Disconnect multiplug from coolant temperature sensor.4. Remove coolant temperature sensor and discard sealing washer.5. Remove coolant temperature sensor from cylinder block.6. Remove steel shim and sealing washer from temperature sensor, discard sealing

washer.

Refit

1. Clean coolant temperature sensor and mating face on cylinder block.2. Fit new sealing washer, then steel shim to coolant temperature sensor.3. Position coolant temperature sensor and tighten to 17 Nm (12.5 lbf.ft).4. Fit thermostat.

*** 26.45.01 Thermostat ***5. Connect battery earth lead.

18.30.12 Sensor - crankshaft position (CKP)

Remove

1. Disconnect battery earth lead.2. Remove engine acoustic cover.

*** 12.30.50 Cover - engine acoustic ***

3. Disconnect CKP sensor multiplug from engine harness.4. Remove underbelly panel.

*** 76.10.50 Panel - underbelly ***

5. Remove bolt securing CKP sensor to gearbox housing and remove sensor.

Refit

1. Clean CKP sensor and mating face.2. Position CKP sensor, fit and tighten bolt to 9 Nm (6.5 lbf.ft).3. Fit underbelly panel.

*** 76.10.50 Panel - underbelly ***4. Connect CKP sensor multiplug to engine harness.5. Fit engine acoustic cover.

*** 12.30.50 Cover - engine acoustic ***6. Connect battery earth lead.

18.30.17 Sensor - throttle position (TP)

Remove

1. Disconnect battery earth lead.2. Remove acoustic cover.

*** 12.30.50 Cover - engine acoustic ***

3. Disconnect multiplug from TP sensor.

4. Remove and discard 2 Torx screws and wave washers securing TP sensor to inlet manifold.

5. Remove TP sensor specification plate.

6. Pull TP sensor from throttle spindle.

CAUTION: Do not twist or apply leverage to throttle position sensor.

Refit

1. Clean mating faces of throttle housing and TP sensor.

2. Fit TP sensor to throttle spindle. Ensure that during fitting the machined flat on the throttle spindle is aligned with the mating portion of the TP sensor

CAUTION: The throttle position sensor can be easily damaged during fitting. When pressing the sensor onto the throttle spindle, use fingers only, and only apply pressure to the area shown shaded in the illustration.

3. Rotate TP sensor in an anti-clockwise direction to align fixing holes.

CAUTION: Do not rotate throttle position sensor in a clockwise direction and ensure that it is not rotated beyond its internal stops.

4. Fit TP sensor specification plate.5. Fit new Torx screws and wave washers, tighten Torx screws to 1.5 Nm (1.1 lbf.ft).6. Connect multiplug to TP sensor.7. Operate throttle cable cam 2 or 3 times and ensure that full travel to the throttle

open and the throttle closed positions is available.8. Fit acoustic cover.

*** 12.30.50 Cover - engine acoustic ***9. Connect battery earth lead.

NOTE: A ‘throttle initialisation’ procedure MUST be carried out using TestBook/T4 whenever the TP sensor is removed or renewed.

18.30.21 Sensor - thermostat monitoring (TM) - KV6 - NAS

Remove

1. Disconnect battery earth lead.2. Remove coolant expansion tank cap to release pressure and refit cap.

WARNING: Since injury such as scalding could be caused by escaping steam or coolant, do not remove the filler cap from the coolant expansion tank while the system is hot.

3. Position absorbent cloth under TM sensor to collect spillage.

4. Disconnect multiplug from TM sensor.5. Release and remove sensor. Discard seal.

Refit

1. Clean sensor and mating face.2. Using a new seal, fit and secure sensor.3. Connect multiplug to sensor.4. Remove absorbent cloth.5. Check for leaks and fill expansion tank to 'MAX' mark.6. Connect battery earth lead.

18.30.24 Sensor - camshaft position (CMP)

Remove

1. Disconnect battery earth lead.2. Remove engine acoustic cover.

*** 12.30.50 Cover - engine acoustic ***

3. Release CMP multiplug from bracket and disconnect multiplug.

4. Remove bolt securing CMP sensor multiplug bracket and release CMP sensor lead from behind bracket.

5. Remove bolt securing CMP sensor to camshaft cover.6. Remove CMP sensor and discard seal.

Refit

1. Clean CMP sensor and mating face.2. Lubricate new seal with clean engine oil and fit to CMP sensor.3. Position CMP sensor, fit and tighten bolt to 8 Nm (6 lbf.ft).4. Feed CMP sensor lead behind multiplug bracket, align bracket, fit bolt and tighten

to 8 Nm (6 lbf.ft).5. Connect CMP sensor multiplug and secure to bracket.6. Fit engine acoustic cover.

*** 12.30.50 Cover - engine acoustic ***7. Connect battery earth lead.

18.30.28 Sensor - knock (KS)

Remove

1. Disconnect battery earth lead.2. Remove LH inlet manifold.

*** 30.15.08 Gasket - inlet manifold - LH ***

3. Disconnect KS multiplug.4. Note the routing of each KS harness.5. Remove 2 bolts securing KS to cylinder block and remove sensors.

Refit

1. Clean KS and mating faces on cylinder block.2. Position KS, ensure that harnesses are correctly routed, fit and tighten bolts to 25

Nm (18 lbf.ft).3. Connect KS multiplug.4. Fit LH inlet manifold.

*** 30.15.08 Gasket - inlet manifold - LH ***5. Connect battery earth lead.6. If a new KS has been fitted, reset ECM adaptions using T4.

18.30.36 Switch - throttle pedal - Non NAS

Remove

1. Remove 2 nuts securing throttle pedal assembly to bulkhead.2. Release clip securing throttle inner cable to throttle pedal and disconnect inner cable

from pedal.3. Disconnect multiplug from throttle pedal switch.4. Remove throttle pedal assembly from vehicle.

5. Release throttle pedal switch from bracket on throttle pedal assembly.6. Release clips securing switch bracket to pedal assembly and remove bracket.

Refit

1. Fit switch bracket to throttle pedal assembly and secure with clips2. Position switch and push fully into bracket on pedal assembly.

3. To correctly position throttle pedal switch, move throttle pedal to the closed position and ensure that switch is in contact with tang on throttle pedal.

4. Connect multiplug to throttle pedal switch.5. Connect throttle inner cable to throttle pedal and secure with clip.6. Position throttle pedal assembly to bulkhead, fit and tighten nuts to 25 Nm (18

lbf.ft).

19.22.26 Sensor - combined - manifold absolute pressure Intake air temperature (MAP IAT)

Remove

1. Disconnect battery earth lead.2. Remove engine acoustic cover.

*** 12.30.50 Cover - engine acoustic ***

3. Disconnect multiplug from MAP/IAT sensor.

4. Remove 2 screws securing MAP/IAT sensor to inlet manifold chamber, remove sensor.

Refit

1. Clean MAP/IAT sensor and mating face on inlet manifold chamber.2. Position MAP/IAT sensor, fit and tighten screws.3. Connect multiplug to MAP/IAT sensor.4. Fit engine acoustic cover.

*** 12.30.50 Cover - engine acoustic ***5. Connect battery earth lead.6. If a new MAP/IAT sensor has been fitted, reset ECM adaptions using T4.

19.22.49 Sensor - throttle position (TP) - NAS - from 03MY

Remove

1. Ensure ignition is switched off.

2. Remove 2 nuts and release throttle pedal and TP sensor assembly from studs.3. Disconnect multiplug from TP sensor.4. Remove throttle pedal and TP sensor assembly.

Refit

1. Position throttle pedal and TP sensor assembly and connect multiplug.2. Fit throttle pedal and TP sensor assembly to studs and tighten nuts to 25 Nm (18

lbf.ft).