ECU LAND ROVER FREELANDER 2001 Owners Manual

ENGINE - K SERIES KV6
OVERHAUL 12-3-83
2.Using sequence shown, remove 8 M8 bolts
securing lower crankcase to cylinder block.
3.Remove remaining M8 bolt and 2 M6 bolts
securing lower crankcase to cylinder block.
4.Remove lower crankcase.
5.Using sequence shown, remove and discard 16
bolts securing bearing ladder to cylinder block.
NOTE: Short length bolts are fitted to the outer
edge of the bearing ladder.
6.Release bearing ladder from dowels and
remove from cylinder block.7.Remove main bearing shells and 2 thrust
washer halves from bearing ladder, keep main
bearing shells in fitted order; discard thrust
washers.
8.Temporarily fit crankshaft pulley bolt.
9.Remove 4 dowel bolts and remove big end
bearing caps from No 1 and No 2 connecting
rods. Keep bearing caps in order.
NOTE: Number stamped below bearing cap
bolt is bearing bore size code. Number
stamped on connecting rod is cylinder number
and letter is weight code.
CAUTION: Do not remove cylinder clamps
LRT-12-144 unless pistons and connecting
rods are to be removed.
10.Release connecting rods from crankshaft.
11.Remove bearing shells from connecting rod
and cap.
12.Rotate crankshaft using pulley bolt, remove
bolts securing remaining connecting rod
bearing caps. Remove bearing caps and
bearing shells from caps. Keep bearing caps in
their fitted order.
M12 6858
M12 6835

ENGINE - K SERIES KV6
OVERHAUL 12-3-87
Refit
1.Fit oil pump gasket.

+ ENGINE - K SERIES KV6,
OVERHAUL, Oil pump - Overhaul.
2.Fit engine sump.

+ ENGINE - K SERIES KV6,
OVERHAUL, Sump - engine oil.
3.Fit crankshaft rear oil seal.

+ ENGINE - K SERIES KV6,
OVERHAUL, Crankshaft rear oil seal.
4.Rotate crankshaft until timing pin LRT-12-232
can be inserted through hole immediately
adjacent to side of lower crankcase and into
elongated hole in drive plate.
CAUTION: Ensure that pin is in elongated
hole. Do not use cast arrow on oil pump
body as a timing mark. Do not remove
timing pin until timing belts are fitted.
5.Fit cylinder head gaskets.

+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - LH.

+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - RH.
Cylinder head gasket - LH
$% 12.29.02.01
Remove
1.Remove and discard camshaft timing belt.

+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.
2.Remove inlet manifold chamber.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, OVERHAUL, Seals -
manifold chamber - up to 03MY.
3.Remove 4 bolts securing LH front camshaft
timing belt cover backplate to cylinder head and
remove backplate.
4.Release HO2S lead from clip on cylinder block.
5.Using sequence shown, loosen then remove 4
nuts securing exhaust manifold to cylinder
head. Remove manifold, remove and discard
gasket.
6.Remove LH camshaft cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - LH - Up to 03MY.
LRT-12-232
M12 7927

ENGINE - K SERIES KV6
12-3-88 OVERHAUL
7.Release clip and disconnect coolant bleed
hose from LH inlet manifold, position hose
aside.
8.Depress locking collar and release breather
hose from LH inlet manifold.
9.Release clips securing RH injector harness to
injector protection cover - if fitted, or from
bosses on fuel rail.10.Remove 2 bolts securing protection cover - if
fitted and RH fuel rail to RH inlet manifold,
remove cover.
11.Remove 2 bolts securing fuel rail to LH inlet
manifold.
12.Release injectors from manifolds and carefully
lay fuel rail and injectors aside.
CAUTION: Always fit plugs to open
connections to prevent contamination.

ENGINE - K SERIES KV6
OVERHAUL 12-3-89
13.Using sequence shown, progressively loosen
and remove 8 cylinder head bolts.
14.Remove cylinder head.
CAUTION: Support both ends of cylinder
head on blocks of wood.
15.Remove and discard cylinder head gasket.
CAUTION: Do not rotate crankshaft with RH
cylinder head fitted.
16.Fit cylinder liner clamps LRT-12-144 and
secure with cylinder head bolts.
CAUTION: Ensure that feet of clamps do not
protrude over bores.Refit
1.Clean cylinder head face.
CAUTION: Use suitable gasket removal
spray and a plastic scraper.
2.Remove bolts securing cylinder liner clamps
LRT-12-144 to cylinder block and remove
clamps.
CAUTION: Do not rotate crankshaft.
3.Clean cylinder block face and dowel holes.
4.Clean cylinder head bolts and wipe dry.
5.Lightly lubricate threads and beneath heads of
cylinder head bolts with clean engine oil.
6.Check that fitted height of dowels is between 10
to 11 mm (0.40 to 0.43 in) above cylinder block
top face. Replace dowels if fitted height is
incorrect.
7.Fit new cylinder head gasket onto cylinder
block with the word 'TOP' uppermost.
8.With assistance, fit cylinder head and carefully
position LH inlet to RH inlet manifold.
9.Carefully enter cylinder head bolts, DO NOT
DROP. Screw bolts into place by hand.

ENGINE - K SERIES KV6
12-3-90 OVERHAUL
10.Tighten cylinder head bolts progressively in the
sequence shown to:
lStage 1 - 25 Nm (18 lbf.ft)
lStage 2 - 25 Nm (18 lbf.ft)
lStage 3 - 25 Nm (18 lbf.ft)
lStage 4 - Using an angle torque gauge,
tighten a bolts in same sequence a further
180°
11.Fit LH camshaft cover gasket.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - LH - Up to 03MY.
12.Remove and discard 'O' rings from injectors.
13.Clean injectors and injector locations in fuel rail.
14.Lubricate new 'O' rings with castor oil and fit to
injectors.
15.Position fuel rail assembly and secure injectors
to inlet manifolds.
16.Position injector protection cover - if fitted to RH
fuel rail and secure injector harness to
protection cover or fuel rail with clips.
17.Fit bolts securing fuel rail to inlet manifolds and
tighten to 9 Nm (7 lbf.ft).
18.Connect coolant bleed hose to inlet manifold
and secure with clip.
19.Connect breather hose to LH inlet manifold.
20.Position ignition coils to LH inlet manifold.
21.Position earth lead, fit nuts and bolts securing
ignition coils to LH inlet manifold and tighten to
9 Nm (7 lbf.ft).
22.Clean camshaft drive belt cover backplate bolts
and apply sealant, Part No. STC 50552 to first
3 threads.
23.Position backplate, fit and tighten bolts to 9 Nm
(7 lbf.ft).
24.Clean exhaust manifold and cylinder head
mating face.25.Fit new exhaust manifold gasket. Position
exhaust manifold, fit nuts and using sequence
shown, tighten to 45 Nm (33 lbf.ft).
26.Secure HO2S lead in clip on cylinder block.
27.Connect HO2S multiplug and secure to support
bracket.
28.Fit new camshaft timing belt.

+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.

ENGINE - K SERIES KV6
OVERHAUL 12-3-91
Cylinder head gasket - RH
$% 12.29.03.01
Remove
1.Remove inlet manifold chamber.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, OVERHAUL, Seals -
manifold chamber - up to 03MY.
2.Remove and discard camshaft timing belt.

+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.
3.Release RH HO2S multiplug from coolant rail
bracket and disconnect multiplug.
4.Using sequence shown, loosen then remove 4
nuts securing RH exhaust manifold to cylinder
head.
5.Remove exhaust manifold, remove and discard
gasket.6.Remove 4 bolts securing RH front timing belt
cover backplate to cylinder head and remove
backplate.
7.Remove RH camshaft cover gasket.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - RH.
8. Up to 03MY: Remove 3 nuts and 3 bolts
securing ignition coils to LH inlet manifold and
release coil earth lead.
9. Up to 03MY:Remove ignition coils and position
aside.
M30 0996

ENGINE - K SERIES KV6
12-3-92 OVERHAUL
10.Release clip and disconnect coolant bleed
hose from RH inlet manifold, position hose
aside.
11.Release injector harness clips from injector
protection cover - if fitted, or from bosses on
fuel rail.
12.Remove 2 bolts securing protection cover - if
fitted and RH fuel rail to RH inlet manifold,
remove cover.13.Remove 2 bolts securing fuel rail to LH inlet
manifold.
14.Release injectors from manifolds and carefully
lay fuel rail and injectors aside.
CAUTION: Always fit plugs to open
connections to prevent contamination.
15.Using sequence shown, progressively loosen
and remove 8 cylinder head bolts.
16.Remove cylinder head.
CAUTION: Support both ends of cylinder
head on blocks of wood.
17.Remove and discard cylinder head gasket.
CAUTION: Do not rotate crankshaft with LH
cylinder head fitted.

ENGINE - K SERIES KV6
OVERHAUL 12-3-93
18.Fit cylinder liner clamps LRT-12-144 and
secure with cylinder head bolts.
CAUTION: Ensure that feet of clamps do not
protrude over bores.
Refit
1.Clean cylinder head face.
CAUTION: Use suitable gasket removal
spray and a plastic scraper.
2.Remove bolts securing cylinder liner clamps
LRT-12-144 to cylinder block and remove
clamps.
CAUTION: Do not rotate crankshaft.
3.Clean cylinder block face, dowels and dowel
holes.
4.Clean cylinder head bolts and wipe dry.
5.Lightly lubricate threads and beneath heads of
cylinder head bolts with clean engine oil.6.Check that fitted height of dowels is between 10
to 11 mm (0.40 to 0.43 in) above cylinder block
top face. Replace dowels if fitted height is
incorrect.
7.Fit new cylinder head gasket onto cylinder
block with the word 'TOP' uppermost.
8.With assistance, fit cylinder head and carefully
position RH inlet to LH inlet manifold.
9.Carefully enter cylinder head bolts, DO NOT
DROP. Screw bolts into place by hand.
10.Using sequence shown, tighten cylinder head
bolts progressively to:
lStage 1 - 25 Nm (18 lbf.ft)
lStage 2 - 25 Nm (18 lbf.ft)
lStage 3 - 25 Nm (18 lbf.ft)
lStage 4 - Further 180°
11.Fit RH camshaft cover gasket.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - RH.
12.Remove and discard lower 'O' rings from
injectors.
13.Clean injectors and injector locations in fuel rail.
14.Lubricate new 'O' rings with castor oil and fit to
injectors.
15.Position fuel rail assembly and secure injectors
to inlet manifolds.

ENGINE - K SERIES KV6
12-3-94 OVERHAUL
16.Position injector protection cover - if fitted to RH
fuel rail and secure injector harness to
protection cover or fuel rail with clips.
17.Fit bolts securing fuel rail to inlet manifolds and
tighten to 9 Nm (7 lbf.ft).
18.Connect coolant bleed hose to inlet manifold
and secure with clip.
19. Up to 03MY:Position ignition coils to LH inlet
manifold.
20. Up to 03MY:Position earth lead, fit nuts and
bolts securing ignition coils to LH inlet manifold
and tighten to 9 Nm (7 lbf.ft).
21.Clean camshaft timing belt cover backplate
bolts and apply sealant, Part No. STC 50552 to
the first 3 threads.
22.Position backplate, fit and tighten bolts to 9 Nm
(7 lbf.ft).
23.Fit new camshaft timing belt.

+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.
24.Clean exhaust manifold and mating face on
cylinder head.
25.Fit new exhaust manifold gasket. Position
exhaust manifold, fit nuts and using sequence
shown, tighten to 45 Nm (33 lbf.ft).
26.Connect RH HO2S multiplug, secure multiplug
in coolant rail bracket.
Cylinder head - decarbonise
$% 12.29.19
Remove
1.Remove cylinder head gaskets.

+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - LH.

+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - RH.
Disassembly
1. LH Cylinder head: Remove 3 bolts securing
LH rear timing belt cover and remove cover.
2. RH Cylinder head: Remove 2 bolts securing
RH rear timing belt cover heat shield to cylinder
head.
3. RH Cylinder head:Remove 3 bolts securing
RH rear timing belt cover; remove cover.
M12 6880
M12 6694

ENGINE - K SERIES KV6
OVERHAUL 12-3-95
4.Position LRT-12-175 to rear camshaft gears as
illustrated, remove and discard bolts securing
gears to camshafts.
5.Remove rear camshaft gears, timing belt and
LRT-12-175 as an assembly.
6.Remove LRT-12-175 from camshaft gears and
remove timing belt from gears. Discard timing
belt.
7.Remove spark plugs.
8.Remove and discard exhaust camshaft cap
seal from cylinder head.
Note: RH cylinder head illustrated.9.Progressively loosen then remove 7 bolts
securing inlet manifold to cylinder head,
remove inlet manifold and discard gasket.
10.Remove 4 bolts securing camshaft front timing
belt cover backplate to cylinder head and
remove backplate.
Note: LH backplate illustrated.
11.Remove 2 bolts securing camshaft rear timing
belt cover backplate to cylinder head and
remove backplate.
Note: LH backplate illustrated.
M12 6882
M12 6883