fuel LAND ROVER FREELANDER 2001 Workshop Manual

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-8 REPAIRS
Gasket - inlet manifold - LH
$% 30.15.08
Remove
1.Disconnect battery earth lead.
2.Drain cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
3.Remove fuel rail.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Fuel rail - KV6 - Non
NAS.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Fuel rail - KV6 - NAS.
4.Depress locking collar and release breather
hose from LH inlet manifold.
5.Release clip and disconnect coolant hose from
LH inlet manifold.
6.Progressively loosen and remove 7 bolts
securing LH inlet manifold to cylinder head.
7.Remove inlet manifold and discard gasket.Refit
1.Clean inlet manifold and cylinder head mating
faces.
2.Fit new inlet manifold gasket to cylinder head,
position inlet manifold, fit and tighten bolts to 25
Nm (18 lbf.ft).
3.Connect breather hose to LH inlet manifold.
4.Connect coolant hose to inlet manifold and
secure clip.
5.Fit fuel rail.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Fuel rail - KV6 - Non
NAS.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Fuel rail - KV6 - NAS.
6.Fill cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
7.Connect battery earth lead.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-13
13.Remove 4 nuts securing manifold and remove
exhaust manifold.
14.Remove and discard manifold and down pipe
gaskets.
Refit
1.Clean exhaust manifold and mating faces.
2.Using new gaskets, fit exhaust manifold and
tighten nuts to cylinder head to 45 Nm (33 lbf.ft)
and nuts to front pipe to 50 Nm (37 lbf.ft).
3.Connect H02S multiplugs, secure multiplugs to
brackets and harness to clips.
4.Clean compressor and mounting bracket
mating faces.
5.Fit compressor heat shield.
6.Position compressor to mounting and align
heat shield. Fit and tighten bolts to 25 Nm (18
lbf.ft).
7.Using a 3/8" square drive socket bar, raise
ancillary drive belt tensioner and fit drive belt to
pulleys.
8.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
9.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
10.Connect battery earth lead.
Seals - inlet manifold chamber - up to
03MY
$% 30.15.37
Remove
1.Disconnect battery earth lead.
2.Remove vacuum enhancer.

+ BRAKES, REPAIRS, Vacuum -
enhancer - KV6.
3.Position absorbent cloth around fuel feed pipe
connection to collect spillage.
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
4.Pull back rubber sleeve on fuel pipe connector,
release connector and disconnect fuel pipe
from fuel rail pipe.
CAUTION: Always fit plugs to open
connections to prevent contamination.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-17
30.Remove and discard seals from inlet manifold
chamber and 'O' rings from RH inlet manifold.Refit
1.Clean seal faces on inlet manifold chamber and
inlet manifolds.
2.Fit new 'O' rings to RH inlet manifold and new
seals to manifold chamber.
3.Position inlet manifold chamber, secure RH coil
harness clips in inlet manifold chamber support
brackets.
4.Connect multiplugs to plug top coils and secure
with locking clips.
5.Align inlet manifold chamber to inlet manifolds,
fit and tighten bolts to 18 Nm (13 lbf.ft).
6.Align inlet manifold chamber support brackets
to RH camshaft cover, fit and tighten bolts to 10
Nm (7.5 lbf.ft).
7.Position engine harness brackets to inlet
manifold chamber, fit and tighten screws.
8.Connect multiplugs to VIS motors.
9. NAS models: Connect engine breather pipe.
10. NAS models: Connect multiplugs to IAT and
MAF sensors.
11.Connect brake servo vacuum hose to inlet
manifold chamber.
12.Connect vacuum/breather hoses to LH and RH
camshaft covers and to throttle body.
13.Connect cruise control actuator vacuum pipe.
14. Non NAS models: Connect vacuum hose to
IACV housing.
15. Non NAS models: Connect multiplugs to TP
and IACV sensors.
16.Connect vacuum/breather hoses to LH
camshaft cover, 'T' piece and purge control
valve.
17. Non NAS models: Connect small vacuum
hose to purge control valve.
18.Connect multiplug to purge control valve .
19.Connect EVAP hose to purge control valve.
20.Connect fuel hose to fuel rail pipe, fit rubber
sleeve over hose connector.
21.Remove absorbent cloth.
22. Non NAS models: Connect throttle inner cable
to throttle cam and secure outer cable in
abutment bracket.
23. Non NAS models: Secure throttle cable in
clips on harness brackets.
24.Adjust throttle cable, if fitted.

+ FUEL DELIVERY SYSTEM -
PETROL, ADJUSTMENTS, Throttle cable -
check and adjust - KV6.
25.Remove vacuum enhancer.

+ BRAKES, REPAIRS, Vacuum -
enhancer - KV6.
26.Connect battery earth lead.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-18 REPAIRS
Seals - inlet manifold chamber - from
03MY
$% 30.15.37
Remove
1.Disconnect battery earth lead.
2.Remove vacuum enhancer.

+ BRAKES, REPAIRS, Vacuum -
enhancer - KV6.
3.Position absorbent cloth around fuel feed pipe
connection to collect spillage.
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
4.Pull back rubber sleeve on fuel pipe connector,
release connector and disconnect fuel pipe
from fuel rail pipe.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Release and disconnect EVAP hose from
purge control valve.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Disconnect multiplug from purge control valve.7. Non NAS models: Disconnect small vacuum
pipe from purge control valve.
8. Non NAS models: Depress locking collar and
release vacuum pipe from IACV housing.
CAUTION: Always fit plugs to open
connections to prevent contamination.
9. Non NAS models: Disconnect multiplug from
IACV.
10. Non NAS models: Disconnect multiplug from
TP sensor.
11. Non NAS models: Depress locking collars and
release vacuum/breather pipe from purge
control valve and LH camshaft cover. Release
clip securing hose to 'T' piece and remove pipe.
CAUTION: Always fit plugs to open
connections to prevent contamination.
M30 1171

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-20 REPAIRS
22. NAS models: Release harness and fuel feed
pipe from clip on inlet manifold chamber.
23.Disconnect multiplugs from VIS motors.
24.Remove 2 screws securing engine harness
brackets to inlet manifold chamber and position
harness aside.25.Remove 2 bolts securing inlet manifold
chamber rear support brackets to RH camshaft
cover.
26.Remove 4 bolts securing inlet manifold
chamber to LH inlet manifold.
M30 1175

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-22 REPAIRS
Refit
1.Clean seal faces on inlet manifold chamber and
inlet manifolds.
2.Fit new 'O' rings to RH inlet manifold and new
seals to inlet manifold chamber.
3.Position inlet manifold chamber, secure RH coil
harness clips in inlet manifold chamber support
brackets.
4.Align inlet manifold chamber to inlet manifolds,
fit and tighten bolts to 18 Nm (13 lbf.ft).
5.Align inlet manifold chamber support brackets
to RH camshaft cover, fit and tighten bolts to 10
Nm (7 lbf.ft).
6.Connect multiplugs to plug top coils and secure
with locking clips.
7.Position engine harness brackets to inlet
manifold chamber, fit and tighten screws.
8.Connect multiplugs to VIS motors.
9. NAS models: Align harness and fuel feed pipe.
Secure harness and pipe in clip on manifold
chamber.
10. NAS models: Using a new clip, fit intake hose
to throttle body and secure hose with clip.
11. NAS models: Connect multiplug to throttle
body.
12. NAS models: Connect multiplugs to IAT and
MAF sensors.
13. NAS models: Fit vacuum/breather pipe and
connect to LH camshaft cover, RH camshaft
cover link pipe and inlet manifold chamber.
14. NAS models: Using a new clip, fit vacuum/
breather pipe to engine air intake hose and
secure pipe with clip.
15. NAS models: Connect vacuum/breather pipe
to LH and RH camshaft covers. Fit pipe into
clip.16. Non NAS models: Connect cruise control
actuator vacuum pipe.
17. Non NAS models: Fit vacuum/breather pipe to
throttle body and connect pipe to LH and RH
camshaft covers.
18. Non NAS models: Fit vacuum/breather pipe to
purge control valve and LH camshaft cover.
Using a new clip, connect pipe to 'T' piece and
secure pipe with clip.
19. Non NAS models: Connect multiplug to TP
sensor.
20. Non NAS models: Connect multiplug to IACV.
21. Non NAS models: Connect vacuum pipe to
IACV.
22. Non NAS models: Connect small vacuum pipe
to purge control valve.
23.Connect multiplug to purge control valve .
24.Connect EVAP hose to purge control valve.
25.Connect fuel hose to fuel rail pipe, fit rubber
sleeve over hose connector.
26. Non NAS models: Connect throttle inner cable
to throttle cam and secure outer cable in
abutment bracket.
27. Non NAS models: Secure throttle cable in
clips on harness brackets.
28. Non NAS models: Adjust throttle cable.

+ FUEL DELIVERY SYSTEM -
PETROL, ADJUSTMENTS, Throttle cable -
check and adjust - KV6.
29.Fit vacuum enhancer.

+ BRAKES, REPAIRS, Vacuum -
enhancer - KV6.
30.Connect the battery earth lead.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-23
Gasket - inlet manifold - RH
$% 30.15.43
Remove
1.Disconnect battery earth lead.
2.Drain cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
3.Remove fuel rail.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Fuel rail - KV6 - Non
NAS.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Fuel rail - KV6 - NAS.
4.Release clip and disconnect coolant hose from
RH inlet manifold.
5.Depress locking collar and release breather
hose from RH inlet manifold.
6.Progressively loosen and remove 7 bolts
securing RH inlet manifold to cylinder head.
7.Remove inlet manifold and gasket.
8.Remove bolt securing coolant breather hose
mounting bracket to inlet manifold and remove
bracket.Refit
1.Clean inlet manifold and cylinder head face.
2.Position coolant/breather hose bracket to inlet
manifold, fit and tighten bolt to 9 Nm (7 lbf.ft).
3.Fit new inlet manifold gasket to cylinder head,
position inlet manifold, fit and tighten bolts to 25
Nm (18 lbf.ft).
4.Connect coolant hose to inlet manifold and
secure clip.
5.Connect breather hose to manifold and secure
into collar.
6.Fit fuel rail.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Fuel rail - KV6 - Non
NAS.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Fuel rail - KV6 - NAS.
7.Fill cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
8.Connect battery earth lead.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-28 OVERHAUL
12. NAS models: Remove clip securing vacuum/
breather pipe to engine air intake hose and
disconnect vacuum/breather pipe from air
intake hose. Discard clip.
CAUTION: Always fit plugs to open
connections to prevent contamination.
13. NAS models: Depress locking collars and
release vacuum/breather pipe from LH
camshaft cover, RH camshaft cover link pipe
and inlet manifold chamber. Remove pipe.
CAUTION: Always fit plugs to open
connections to prevent contamination.
14. NAS models: Disconnect multiplug from IAT
and MAF sensors.
15. NAS models: Disconnect multiplug from
throttle body.
16. NAS models: Remove clip securing intake
hose to throttle body, remove intake hose and
MAF sensor assembly. Discard clip.
17. NAS models: Release harness and fuel feed
pipe from clip on inlet manifold chamber.
18.Disconnect multiplugs from VIS motors.19.Remove 2 screws securing engine harness
brackets to inlet manifold chamber and position
harness aside.
20.Release 3 locking clips and disconnect 3
multiplugs from RH plug top coils.
21.Release 2 clips securing RH plug top coil
harness to inlet manifold chamber support
brackets.
M30 1173
M30 1176

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-30 OVERHAUL
Refit
1.Clean seal faces on inlet manifold chamber and
inlet manifolds.
2.Fit new 'O' rings to RH inlet manifold and new
seals to inlet manifold chamber.
3.Fit inlet manifold chamber to inlet manifolds
and tighten bolts to 18 Nm (13 lbf.ft).
4.Align inlet manifold chamber support brackets
to RH camshaft cover, fit and tighten bolts to 10
Nm (7 lbf.ft).
5.Position engine harness brackets to inlet
manifold chamber, fit and tighten screws.
6.Secure RH plug top coil harness to manifold
chamber support brackets.
7.Connect multiplugs to plug top coils and secure
with locking clips.
8.Connect multiplugs to VIS motors.
9. NAS models: Align harness and fuel feed pipe.
Secure harness and pipe in clip on manifold
chamber.
10. NAS models: Using a new clip, fit intake hose
to throttle body and secure hose with clip.
11. NAS models: Connect multiplug to throttle
body.
12. NAS models: Connect multiplugs to IAT and
MAF sensors.13. NAS models: Fit vacuum/breather pipe and
connect to LH camshaft cover, RH camshaft
cover link pipe and inlet manifold chamber.
14. NAS models: Using a new clip, fit vacuum/
breather pipe to engine air intake hose and
secure pipe with clip.
15. NAS models: Connect vacuum/breather pipe
to LH and RH camshaft covers. Fit pipe into
clip.
16. Non NAS models: Fit vacuum/breather pipe to
throttle body and connect pipe to LH and RH
camshaft covers.
17. Non NAS models: Fit vacuum/breather pipe to
purge control valve and LH camshaft cover.
Using a new clip, connect pipe to 'T' piece and
secure pipe with clip.
18. Non NAS models: Connect multiplug to TP
sensor.
19. Non NAS models: Connect multiplug to IACV.
20. Non NAS models: Connect vacuum pipe to
IACV.
21. Non NAS models: Connect small vacuum pipe
to purge control valve..
22.Connect multiplug to purge control valve .
23.Fit vacuum enhancer and connect to inlet
manifold chamber.
24.Using a new clip, connect vacuum enhancer to
intake hose and secure hose with clip.

AUTOMATIC GEARBOX - JATCO
44-22 REPAIRS
42.Remove 2 top bolts securing gearbox to
engine.
43.Release gearbox from 2 dowels.
44.Manoeuvre and lower gearbox to floor.
45.Fit converter retaining plate and secure with
bolts.Refit
1.Remove torque converter retaining plate.
2.Ensure converter is fully located in oil pump
drive by checking depth 'A' as illustrated. Depth
A = 4 mm.
3.Clean gearbox to engine mating faces, dowels
and dowel holes.
4.Fit gearbox assembly.
5.Fit bolts securing gearbox and tighten to 85 Nm
(63 lbf.ft).
6.Position LH mounting bracket to gearbox, fit
and tighten bolts to 85 Nm (63 lbf.ft).
7.Position LH mounting to body, fit and tighten
bolts to 48 Nm (35 lbf.ft).
8.Align gearbox bracket to LH body mounting, fit
and tighten through bolt to 100 Nm (74 lbf.ft).
9.Disconnect lifting equipment.
10.Remove nuts and bolts securing lifting brackets
to gearbox and remove brackets.
11.Connect engine and gearbox harness
multiplugs to main harness.
12.Secure multiplugs to clips.
13.Position engine earth lead and secure with bolt.
14.Fit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - KV6.
15.Clean throttle housing and manifold chamber
mating faces.
16.Fit new seal to inlet manifold chamber.
17.Position throttle housing to manifold chamber,
fit Torx screws and tighten to 7 Nm (7 lbf.ft).
18.Connect throttle inner cable to throttle cam and
secure outer cable in abutment bracket, if fitted.
19.Connect hose to cruise control actuator.
20.Secure breather hoses to throttle housing, if
fitted.
21.Adjust throttle cable, if fitted.

+ FUEL DELIVERY SYSTEM -
PETROL, ADJUSTMENTS, Throttle cable -
check and adjust - KV6.
22.Clean CKP sensor and mating face.
M44 1689
A
M44 1668