ECU LAND ROVER FREELANDER 2001 Workshop Manual

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-5
Intermediate pipe - NAS
$% 30.10.11
Remove
1.Raise vehicle on 4 post ramp.
2.Remove tail pipe and silencer.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Tail pipe &
silencer.
3.Remove 2 nuts securing intermediate pipe to
front pipe.
4.Loosen nut securing intermediate pipe clamp to
catalyst.
5.Release intermediate pipe from mounting.
6.Release and remove intermediate pipe.
7.Remove and discard gasket.Refit
1.Clean intermediate pipe and mating faces.
2.Fit new gasket to front pipe flange.
3.Fit intermediate pipe and connect mounting.
4.Tighten intermediate pipe flange nuts to 60 Nm
(44 lbf.ft).
5.Tighten clamp nut to 55 Nm (40 lbf.ft).
6.Fit tail pipe and silencer.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Tail pipe &
silencer.
7.Lower vehicle.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-7
Heat shield - A/C compressor - KV6 - NAS
$% 30.10.32
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Using a 3/8” square drive socket bar, raise
ancillary drive belt tensioner and release drive
belt from alternator pulley.
4.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Remove 3 bolts securing A/C compressor to
fixing brackets and position compressor aside.
6.Remove compressor heat shield.Refit
1.Clean compressor and mounting bracket
mating faces.
2.Fit compressor heat shield.
3.Position compressor to mounting and align
heat shield. Fit and tighten bolts to 25 Nm (18
lbf.ft).
4.Using a 3/8" square drive socket bar, raise
ancillary drive belt tensioner and fit drive belt to
pulleys.
5.Fit underbelly panel.

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

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
7.Connect battery earth lead.
M30 1142

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 30-3-9
Gasket - exhaust manifold - RH - Non
NAS
$% 30.15.16
Remove
1.Disconnect battery earth lead.
2.Release RH HO2S multiplug from coolant rail
bracket and disconnect multiplug.
3.Remove bolt securing upper RH engine steady
to top arm.
4.Loosen bolt securing upper RH engine steady
to body, pivot engine steady away from top
arm.
5.Raise vehicle on a ramp.
6.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
7.Remove exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - Non
NAS.8.Remove bolt securing lower engine steady to
sump mounting bracket.
9.Loosen bolt securing lower engine steady to
subframe, pivot steady away from sump
mounting bracket.
10.Remove cable tie and release gear selector
cable from clip on body.
11.Remove 2 bolts securing IRD heat shield to
lower engine steady mounting bracket.
12.Remove nut securing heat shield to IRD pinion
housing.
13.Remove nut securing heat shield to IRD
housing and remove heat shield.
M30 0996
M12 6597

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-10 REPAIRS
14.Remove 4 nuts securing RH exhaust manifold
to cylinder head.
15.Remove exhaust manifold, remove and discard
gasket.
Refit
1.Clean exhaust manifold and mating face on
cylinder head.
2.Fit new exhaust manifold gasket, position
exhaust manifold, fit nuts and tighten to 45 Nm
(33 lbf.ft).
3.Position heat shield to IRD unit.
4.Fit nut securing heat shield to IRD housing and
tighten to 45 Nm (33 lbf.ft).
5.Fit nut securing heat shield to IRD pinion
housing and tighten to 25 Nm (18 lbf.ft).
6.Fit 2 bolts securing heat shield to lower engine
steady mounting bracket and tighten to 9 Nm (7
lbf.ft).
7.Fit gear selector cable in body clip and secure
with cable tie.
8.Position lower engine steady to sump
mounting, fit and tighten bolt to 100 Nm (74
lbf.ft).
9.Tighten bolt securing lower engine steady to
subframe to 100 Nm (74 lbf.ft).
10.Fit exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - Non
NAS.
11.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
12.Lower vehicle on ramp.
13.Connect RH HO2S multiplug, secure multiplug
in coolant rail bracket.
14.Position upper RH engine steady to top arm, fit
and tighten bolt to 100 Nm (74 lbf.ft).
15.Tighten bolt securing upper RH engine steady
to body to 100 Nm (74 lbf.ft).
16.Connect battery earth lead.
Gasket(s) - exhaust manifold - RH - KV6 -
NAS
$% 30.15.16
Remove
1.Disconnect battery earth lead.
2.Remove RH catalytic converter.

+ EMISSION CONTROL, REPAIRS,
Catalytic converter - RH - KV6 - NAS.
3.Remove 4 nuts securing exhaust manifold to
cylinder head, remove manifold and discard
gasket.
Refit
1.Clean exhaust manifold and mating face.
2.Using new gasket, fit exhaust manifold and
tighten nuts to 45 Nm (33 lbf.ft).
3.Fit RH catalytic converter.

+ EMISSION CONTROL, REPAIRS,
Catalytic converter - RH - KV6 - NAS.
4.Connect battery earth lead.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-11
Gasket - exhaust manifold - LH - Non
NAS
$% 30.15.17
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Release HO2S multiplug from support bracket
on LH camshaft cover, disconnect multiplug.
4.Raise vehicle on ramp.
5.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
6.Remove 2 nuts securing front exhaust pipe to
manifold flange.
7.Lower vehicle on ramp.8.Release HO2S lead from clip on cylinder block.
Remove 4 nuts securing exhaust manifold to
cylinder head, remove manifold and discard
gasket.
Refit
1.Clean exhaust manifold and mating face on
cylinder head.
2.Fit new exhaust manifold gasket to cylinder
head.
3.Position exhaust manifold to cylinder head, fit
and tighten nuts to 45 Nm (33 lbf.ft).
4.Raise vehicle on ramp.
5.Position LH exhaust manifold flange to front
pipe, fit and tighten nuts to 50 Nm (37 lbf.ft).
6.Secure HO2S lead in clip on cylinder block.
7.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
8.Lower vehicle on ramp.
9.Connect HO2S multiplug and secure to support
bracket.
10.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
11.Connect battery earth lead.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-12 REPAIRS
Gasket(s) - exhaust manifold - LH - NAS
$% 30.15.17
Remove
1.Position vehicle on 4 post ramp.
2.Disconnect battery earth lead.
3.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
4.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Using a 3/8" socket bar raise ancillary drive belt
tensioner and release drive belt from alternator
and PAS pump pulleys.
6.Remove 3 bolts securing A/C compressor to
fixing brackets and position compressor aside.
7.Remove compressor heat shield.8.Release and disconnect HO2S multiplug.
9.Release HO2S harness from clip.
10.Release and disconnect post catalyst HO2S
multiplug.
11.Release HO2S harness from clips.
12.Remove 2 nuts securing exhaust front pipe to
exhaust manifold.
M30 1142
M19 3505
M19 3481

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
30-3-14 REPAIRS
5.Release clip and disconnect 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
hose from purge control valve.
8. Non NAS models: Depress locking collar and
release vacuum hose from IACV housing .
9. Non NAS models: Disconnect multiplug from
IACV.
10. Non NAS models: Disconnect multiplug from
TP sensor.
11.Depress locking collars and release vacuum/
breather hose from purge control valve and LH
camshaft cover. Release clip securing hose to
'T' piece and remove hose.
12.Depress locking collars and release vacuum/
breather hoses from throttle body, LH and RH
camshaft cover and remove hose.13. Non NAS models: Release throttle cable from
clips on harness brackets.
14. Non NAS models: Release throttle cable from
abutment bracket and disconnect cable from
throttle body cam.
15. NAS models: Disconnect multiplugs from IAT
and MAF sensors.
16. NAS models: Disconnect engine breather pipe
from intake hose.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-15
17. NAS models: Disconnect injector air supply
pipe from intake hose.
18. NAS models: Disconnect multiplug from
throttle body.
19. NAS models: Release clip and remove intake
hose and MAF sensor assembly.
20.Disconnect cruise control actuator vacuum
pipe.21.Depress locking collar and disconnect brake
servo hose from inlet manifold chamber.
22.Disconnect multiplugs from VIS motors.
23.Remove 2 screws securing engine harness
brackets to inlet manifold chamber and position
harness aside.
M19 3198