oil LAND ROVER FREELANDER 2001 Workshop Manual

ENGINE - K SERIES KV6
REPAIRS 12-3-75
Refit
NOTE: Following front or rear timing belt
refitment, it is possible that after rotating the
engine and positioning the crankshaft pulley to
the 'SAFE' position, the timing marks on the
rear timing gears may be misaligned. This
misalignment is acceptable provided that the
timing belt refitting procedure was carried out
correctly.
1.Clean camshaft gears and mating faces on
camshafts.
CAUTION: If the sintered gears have been
subjected to prolonged oil contamination,
they must be soaked in a solvent bath and
then thoroughly washed in clean solvent
before refitting. Because of the porous
construction of sintered material, oil
impregnated in the gears will emerge and
contaminate the belt.
2.Place gears inverted on a flat surface, with the
locating lugs on the gears positioned as
illustrated.3.Keeping the timing marks aligned, position
timing belt onto gears.
4.Position LRT-12-195 between the gears, turn
centre nut sufficiently to spread drive belt.
5.Invert gears and timing belt and position LRT-
12-175 to camshaft gears.
6.Check that the locating lugs are correctly
aligned and remove LRT-12-195 from between
camshaft gears.

ENGINE - K SERIES KV6
12-3-78 OVERHAUL
2.Cylinder liners have their bore/grade and step
height determined at manufacture. The bore/
grade, red, blue (A) or (B), and step heights V
or Z together with the cylinder liner part number
and colour code are marked on the external
diameter of the cylinder liners. If cylinder(s) are
to be replaced, the replacement liner(s) must
have the same step height as the original
liner(s). Both step heights are available in red
(A) and blue (B) grades of cylinder liners.

+ GENERAL DATA, Engine - KV6
Petrol.
3.Check pistons for distortion and cracks.
NOTE: Piston grades A or B are stamped on
the crown of the piston.
4. Piston diameter check: Measure piston
diameter at right angles to gudgeon pin and 8
mm (0.3 in) from bottom of skirt.

+ GENERAL DATA, Engine - KV6
Petrol.
NOTE: Piston and connecting rods are only
supplied as an assembly.
CAUTION: Ensure pistons are retained with
their respective cylinder liners.
5.Position piston in cylinder liner and measure
clearance 20 mm (0.75 in) from bottom of
cylinder liner.

+ GENERAL DATA, Engine - KV6
Petrol.6. Piston ring gap: Position new top and second
compression piston rings 20 mm (0.75 in) from
top of cylinder bore and measure ring gaps.

+ GENERAL DATA, Engine - KV6
Petrol.
CAUTION: Ensure piston rings are kept
square to liner bore. Retain rings with the
piston fitted to the liner in which they were
checked.
7. Piston rings - refit:Using a suitable expander,
fit oil control spring.
8.With 'TOP' or identification markings to top of
piston, use an expander to fit piston rings in
sequence; oil control, 2nd and top
compression.
NOTE: The second compression ring is
stepped.
M12 6838

ENGINE - K SERIES KV6
OVERHAUL 12-3-79
9.Ensure rings are free to rotate, position
compression ring gaps A and B at 120° to each
other and away from thrust side. Position oil
control ring gap C and spring gap D at 30° on
opposite side of gudgeon pin axis.
10.Check clearance of each piston ring to its
respective groove.

+ GENERAL DATA, Engine - KV6
Petrol.Reassembly
1.Clean cylinder liners and liner recess in cylinder
block.
2.Lubricate cylinder liner bores, pistons and rings
with clean engine oil, ensure ring gaps are
correctly spaced.
3.Clean bearing shell recesses in connecting
rods and bearing caps.
4.Fit piston ring clamp, LRT-12-204 to each
piston in turn and fit piston to its respective
cylinder liner ensuring that when fitted, arrow
on piston crown will be towards front of engine.
CAUTION: Do not push pistons fully down
bores at this stage.
5.Remove piston ring clamp.
6.Apply a 2.00 mm (0.1 in) thick continuous bead
of sealant, Part No. RTC 3347, around
shoulder of each cylinder liner as shown.
7.Keeping cylinder liner 'square' to cylinder block,
push each liner fully down until shoulder of liner
seats against cylinder block ensuring that the
arrow on the piston is towards front of engine.
8.To prevent cylinder liners from being displaced,
position LRT-12-144 cylinder liner clamps and
secure to cylinder block with cylinder head
bolts. Ensure that feet of clamps do not
protrude over liner bores.
9.Fit crankshaft.

+ ENGINE - K SERIES KV6,
OVERHAUL, Crankshaft.
M12 6839
D
BA
C
M12 6842

ENGINE - K SERIES KV6
12-3-80 OVERHAUL
Crankshaft front oil seal
$% 12.21.14.01
Remove
1.Remove camshaft timing belt.

+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.
2.Remove crankshaft drive gear.
3.Fit thrust button, LRT-12-200/3 to end of
crankshaft.
4.Screw LRT-12-200 into crankshaft front oil
seal.
5.Tighten centre bolt of LRT-12-200 to remove oil
seal.
6.Remove and discard oil seal from LRT-12-200.
7.Remove thrust button from crankshaft.Refit
1.Clean oil seal recess in oil pump and running
surface on crankshaft, ensure bolt holes are
clean and dry.
2.Fit oil seal guide from seal kit, over end of
crankshaft.
3.Position new seal on crankshaft up against oil
pump housing. Drift seal into place using tool
LRT-12-202.
CAUTION: Oil seal must be fitted dry.
4.Remove LRT-12-202 and oil seal guide from
crankshaft.
5.Clean crankshaft gear and wipe end of
crankshaft.
6.Fit drive gear to crankshaft.
7.Fit camshaft timing belt.

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

ENGINE - K SERIES KV6
OVERHAUL 12-3-81
Crankshaft rear oil seal
$% 12.21.20.01
Remove
1.Remove automatic gearbox.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gearbox - KV6 - with engine and
gearbox removed.
2.Assemble LRT-12-161 to LRT-12-199 and
secure with clamp bolt.
3.Position LRT-12-161 and LRT-12-199 to
crankshaft pulley to restrain crankshaft.
4.With assistance, remove and discard 6 bolts
securing drive plate to crankshaft.
5.Remove drive plate from crankshaft.6.Remove and discard 5 bolts securing
crankshaft rear oil seal housing to cylinder
block.
7.Remove crankshaft rear oil seal.
Refit
1.Clean cylinder block face and oil seal running
surface on crankshaft, ensure bolt holes are
clean and dry.
2.Position oil seal protector, LRT-12-061 to
crankshaft.
3.Position oil seal to crankshaft.
CAUTION: Oil seal must be fitted dry.

ENGINE - K SERIES KV6
12-3-82 OVERHAUL
4.Fit new Patchlok bolts securing oil seal to
cylinder block and using sequence shown,
tighten to 8 Nm (6 lbf.ft).
5.Remove oil seal protector LRT-12-061.
6.Clean bolt holes in crankshaft using an old
drive plate bolt with two saw cuts at an angle of
45° to the bolt shank.
7.Clean drive plate and mating face of
crankshaft.
8.Position drive plate to crankshaft and fit but do
not tighten new Patchlok bolts.
9.Position LRT-12-161 and LRT-12-199 to
crankshaft pulley to restrain crankshaft.
10.Using sequence shown, tighten to bolts to:
lStage 1 - 25 Nm (18 lbf.ft)
lStage 2 - 100 Nm (74 lbf.ft)
11.Remove special tool from crankshaft pulley,
loosen bolt and remove LRT-12-161 from LRT-
12-199.
12.Fit automatic gearbox.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gearbox - KV6 - with engine and
gearbox removed.
Crankshaft
$% 12.21.33.01
Remove
1.Remove cylinder head gaskets.

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

+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - RH.
2.Remove oil pump gasket.

+ ENGINE - K SERIES KV6,
OVERHAUL, Oil pump - Overhaul.
3.Remove crankshaft rear oil seal.

+ ENGINE - K SERIES KV6,
OVERHAUL, Crankshaft rear oil seal.
4.Remove engine sump.

+ ENGINE - K SERIES KV6,
OVERHAUL, Sump - engine oil.
Disassembly
1.Remove bolt securing oil pick up strainer,
remove strainer and discard 'O' ring.

ENGINE - K SERIES KV6
OVERHAUL 12-3-85
9. Big-end bearings selection: Select the
required bearing shells from general data.

+ GENERAL DATA, Engine - KV6
Petrol.
10.Ensure all bolt holes are clean and dry.
Remove all traces of thread locking material
from oil pick-up strainer bolt hole and threads of
retaining bolt.
CAUTION: Do not use a tap.
11.Ensure bearing ladder locating dowels are
fitted and dowel holes in bearing ladder are
clean and dry.
12.Check coolant stub pipe in cylinder block for
signs of leakage and corrosion, replace as
necessary. Apply sealant, Part No. STC 50554
to seal replacement pipe to cylinder block.
13.Clean main bearing shell recesses in cylinder
block.
14.Clean crankshaft main bearing and big end
bearing journals. Clean bearing shell locations
in connecting rods and caps.
15.Fit selected main bearing shells, grooved into
cylinder block and plain into bearing ladder.
16.Fit new thrust washers to cylinder block.
17.Position DTI gauge stylus on end of crankshaft
as illustrated, push crankshaft away from DTI,
zero DTI gauge, push crankshaft in the
opposite direction and note reading on gauge.

+ GENERAL DATA, Engine - KV6
Petrol.
CAUTION: If end-float exceeds limits given,
crankshaft must be replaced.Reassembly
1.Fit selected big-end bearing shells to
connecting rods and caps.
2.Lubricate crankshaft journals with clean engine
oil. Hold crankshaft with big end journals
horizontal, lower crankshaft into main bearings.
3.Carefully pull connecting rods into place, fit
connecting rod caps noting that featherways
are on opposite sides; fit and lightly tighten
dowel bolts.
4.Tighten dowel bolts to:
lStage 1 - 20 Nm (15 lbf.ft)
lStage 2 - Further 45°
5.Using a lint free cloth and a suitable cleaning
solvent, clean bearing ladder and mating face
on cylinder block.
6.Apply clean engine oil to crankshaft thrust
washers and fit to bearing ladder with oil
grooves facing outwards.
7.Fit bearing ladder and ensure that all bearing
shells are seated correctly.
8.Noting that longest bolts must be fitted in inner
holes in bearing ladder, fit new bolts and tighten
to:
lStage 1 - 20 Nm (15 lbf.ft)
lStage 2 - Further 90°
9.Using a lint free cloth and a suitable cleaning
solvent, clean mating surfaces on cylinder
block and lower crankcase.

ENGINE - K SERIES KV6
12-3-86 OVERHAUL
10.Apply a continuous bead of sealant, Part No.
STC 50550, to paths on lower crankcase as
shown then spread to an even film using a
roller.
CAUTION: To avoid contamination,
assembly must be completed immediately
after application of sealant.
11.Fit 2 M8 slave guide studs into cylinder block at
positions shown.
12.Position lower crankcase to cylinder block.13.Fit and lightly tighten 6 M8 bolts, remove guide
studs, fit and lightly tighten 2 remaining M8
bolts.
14.Using sequence shown, tighten bolts to 25 Nm
(18 lbf.ft).
15.Fit and tighten remaining M8 bolt to 25 Nm (18
lbf.ft).
16.Fit 2 rear M6 bolts and tighten to 9 Nm (7 lbf.ft).
17.Clean oil pick-up strainer and mating face.
18.Lubricate new 'O' ring with clean engine oil and
fit to pick-up strainer.
CAUTION: Ensure 'O' ring, Part No. LYX
000210L is used.
19.Apply sealant, Part No. STC 50552 to threads
of oil pick-up strainer retaining bolt.
20.Position oil pick-up strainer, fit and tighten bolt
to 25 Nm (18 lbf.ft).
21.Clean oil pump, oil seal recess in oil pump body
and mating face on cylinder block, ensure bolt
holes are clean and dry.
22.Clean oil seal running surface on crankshaft.

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
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.