oil LAND ROVER FREELANDER 2001 Workshop Manual

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
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
12-3-96 OVERHAUL
12.Check end-float of camshafts using a DTI.

+ GENERAL DATA, Engine - KV6
Petrol.
CAUTION: If camshaft end-float exceeds
limits given, repeat check with new
camshaft(s). If end-float is still excessive,
replace cylinder head and camshaft carrier
as an assembly.
13.Using sequence shown, progressively loosen
22 bolts securing camshaft carrier to cylinder
head until valve spring pressure is released
and remove bolts.
14.Remove camshaft carrier.15.Remove camshafts and discard oil seals.
Note: Inlet camshafts are colour coded orange,
exhaust camshafts
16.Using a stick magnet, remove 12 hydraulic
tappets from cylinder head.
CAUTION: Store hydraulic tappets in their
fitted order and store upright. Maintain
absolute cleanliness when handling
hydraulic tappets. Failure to observe these
precautions can result in engine failure.
17.Measure the outside diameter of hydraulic
tappets.

+ GENERAL DATA, Engine - KV6
Petrol.
Note: Measurement must be taken half-way
along tappet body.
18.Using LRT-12-034, and adapter LRT-12-034/1,
compress valve spring, remove 2 collets,
release valve spring and remove LRT-12-034.
19.Remove valve spring cap and valve spring.
20.Remove valve from cylinder head.

ENGINE - K SERIES KV6
OVERHAUL 12-3-97
21.Remove valve stem oil seal using LRT-12-071.
Discard stem seal.
22.Repeat procedure for remaining valves,
keeping components in their fitted order.
Inspect
1.Clean camshafts, bearing running surfaces in
carrier and cylinder head, carrier and cylinder
head mating faces.
2.Inspect camshafts and replace camshafts if
scored, pitted or excessively worn.
3.Position camshafts in cylinder head and place
Plastigauge across each journal.
CAUTION: Ensure camshafts are in their
correct fitted locations. Camshafts are
colour coded - Inlet - Orange; Exhaust -
Blue.
4.Refit camshaft carrier, fit bolts and using
sequence shown, tighten to 10 Nm (7.5 lbf.ft).
Do not rotate camshafts.5.Using the sequence shown, progressively
loosen and remove camshaft carrier bolts.
Release and remove camshaft carrier from
cylinder head.
6.Measure widest part of Plastigauge on each
journal.

+ GENERAL DATA, Engine - KV6
Petrol.
7.If clearance is excessive, fit new camshafts and
repeat check. If clearance is still excessive
renew cylinder head.
8.Remove all traces of Plastigauge using an oily
rag.
9.Clean sealing surfaces of cylinder heads.
Clean inlet and exhaust manifold mating faces.
CAUTION: Do not use a metal scraper.
10.Decarbonise combustion areas of cylinder
heads
11.Blow out all oilways and coolant passages.
12.Check cylinder head for damage, pay particular
attention to sealing faces.
M12 6889
LRT-12-071
mm.025.038.051.076
M12 6887

ENGINE - K SERIES KV6
12-3-100 OVERHAUL
31.Check that fitted height of valve guide, 'A', is
6.00 mm (0.24 in).
32.Check condition of valve seats and existing
valves that are to be re-used.
33.Renew valve seat inserts as necessary.
CAUTION: Do not damage counterbore
when removing insert.
34.Cool replacement valve seat inserts using
liquid nitrogen and press into cylinder head in
one continuous operation.
CAUTION: Do not heat cylinder head.
Inserts must not stand proud of combustion
face on completion of cutting operation.
35.Cut valve seats using a suitable pilot and the
following cutters:
l15° - To cut first angle
l45° - Make final cut and remove any burrs
l60° - To narrow seat and obtain correct
valve seat width
36.Check valve seat width and face angle:
lSeat width - 'A' - Inlet = 1.2 mm (0.05 in);
Exhaust = 1.6 mm (0.06 in)
lValve face angle - 'B' - Inlet and exhaust =
45°
37.Lap each valve to its seat using grinding paste.38.Apply Prussian Blue to valve seat, insert valve
and press it into position several times without
rotating. Remove and check valve for even and
central seating: seating position shown by
Prussian Blue should be in the centre of valve
face: a: High towards stem, increase 60° cut
and restore seat width. b: Low towards edge,
increase 45° cut and restore seat width. Lap
and recheck valve seating.
39.Check valve stem fitted height - 'A'.

+ GENERAL DATA, Engine - KV6
Petrol.
CAUTION: If valve stem fitted height is
above service limit, fit new valve and re-
check. If still over limit, renew valve seat
insert.
40.Clean valve springs and lubricate valves.
Reassembly
1.Lubricate new valve stem oil seals with clean
engine oil.
2.Using tool LRT-12-071 fit new valve stem oil
seals.
3.Fit valves.
M12 7894
A

ENGINE - K SERIES KV6
OVERHAUL 12-3-101
4.Fit spring and spring cap.
5.Position LRT-12-034 and adapter LRT-12-
034/1to spring cap and compress valve spring.
6.Fit collets.
7.Release valve spring and remove tool LRT-12-
034.
8.Using a wooden dowel and mallet, lightly tap
top of each valve two or three times to seat
valves and collets.
9.Thoroughly clean and lubricate hydraulic
tappets with clean engine oil. Fit hydraulic
tappets to original bores in cylinder head.
10.Ensure that mating faces of camshaft carrier
and cylinder head are clean and dry.
11.Lubricate camshafts and bearing journals with
clean engine oil.
12.Position camshafts in cylinder head with rear
timing gear drive slots in each camshaft facing
towards the centre as shown.
CAUTION: Ensure camshafts are in their
correct fitted locations. Camshafts are
colour coded - Inlet - Orange; Exhaust -
Blue.13.Apply continuous thin beads of sealant, Part
No. STC 4600, to paths on camshaft carrier as
shown. Spread sealant to an even film using a
roller.
CAUTION: To avoid contamination,
assembly should be completed immediately
after application of sealant.
14.Position camshaft carrier, fit and progressively
tighten bolts in the sequence shown to 10 Nm
(7.5 lbf.ft).

ENGINE - K SERIES KV6
12-3-102 OVERHAUL
15.Noting that the front camshaft oil seals are
black in colour and the rear oil seals are red, fit
new camshaft oil seals using LRT-12-203 and
LRT 12-148A
CAUTION: Oil seals must be fitted dry. Do
not use tool LRT-12-148 for fitting seals.
16.Clean camshaft timing belt cover backplate
bolts and apply sealant, Part No. STC 50552 to
the first 3 threads.
17.Position camshaft timing belt rear cover
backplates to cylinder head, fit and tighten bolts
to 9 Nm (7.5 lbf.ft).
18.Fit spark plugs.
19.Clean rear camshaft gears and mating faces on
camshafts.
CAUTION: If sintered gears have been
subjected to prolonged oil contamination,
they must be soaked in solvent 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 timing belts.20.Place gears inverted on a flat surface, with the
locating lugs on the gears positioned as
illustrated.
21.Keeping the timing marks aligned, position
timing belt onto gears.
22.Position LRT-12-195 between the gears, turn
centre nut sufficiently to spread drive belt.
23.Invert gears and timing belt and position LRT-
12-175 to camshaft gears.
24.Check that locating lugs are still aligned and
remove LRT-12-195 from between camshaft
gears.

ENGINE - K SERIES KV6
12-3-104 OVERHAUL
Oil pump - Overhaul
$% 12.60.32
Remove
1.Remove oil pump gasket.

+ ENGINE - K SERIES KV6, REPAIRS,
Gasket - oil pump.
Disassembly
1.Remove 4 Torx screws securing cover plate to
oil pump body.
CAUTION: Do not allow cover to separate
from pump body.
2.Invert oil pump.
3.Carefully remove cover plate from oil pump
body taking care to ensure that rotors are
retained in pump body.
Note: Cover plate is dowel located.4.Remove and discard cover plate sealing ring.
5.Make suitable alignment marks between inner
and outer rotors and pump body.
6.Remove inner and outer rotors.
7.Clean inner and outer rotors and rotor housing.
8.Fit inner and outer rotors ensuring that
reference marks are aligned.
Inspect
1.Check rotor clearances:
lOuter rotor to body = 0.13 - 0.23 mm
(0.0051 - 0.0091 in)
lInner rotor tip = 0.05 - 0.13 mm (0.002 -
0.005 in)
lInner and outer rotor end-float = 0.04 - 0.09
mm (0.0016 - 0.0035 in)
2.Renew oil pump as an assembly if clearances
are excessive.