alternator LAND ROVER FREELANDER 2001 User Guide

ENGINE - K SERIES KV6
12-3-114 OVERHAUL
35.Position ancillary belt tensioner, fit bolts and
tighten to 25 Nm (18 lbf.ft).
36.Clean LH and RH front timing belt covers.
37.Position LH and RH front timing belt covers, fit
and tighten bolts to 4 Nm (3 lbf.ft).
38.Clean idler pulley, position pulley to engine
front mounting plate and tighten Torx bolt to 45
Nm (33 lbf.ft).
39.Position alternator to front mounting plate.
40.Fit bolt and nut and bolt securing alternator to
front mounting plate and tighten to 45 Nm (33
lbf.ft).
41.Connect alternator multiplug.
42.Connect battery lead to alternator, fit and
tighten nut to 8 Nm (6 lbf.ft), fit terminal cover.
43.Clean LH rear timing belt cover.
44.Position LH rear timing belt cover, fit and
tighten bolts to 4 Nm (3 lbf.ft).
45.Clean RH rear timing belt cover.
46.Position RH rear timing belt cover, fit bolts and
tighten to 4 Nm (3 lbf.ft).
47.Position heat shield, fit bolts and tighten M6 bolt
to 9 Nm (7 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).
48.Fit inlet manifold chamber - if fitted.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.
49.Position ancillary drive belt to crankshaft and
alternator pulleys.
50.Position engine mounting front bracket to
engine front plate and tighten bolts to 45 Nm
(33 lbf.ft).

FUEL DELIVERY SYSTEM - PETROL
19-2-36 REPAIRS
10.Remove fuel rail.
CAUTION: Always fit plugs to open
connections to prevent contamination.
11.Remove and discard 'O' rings from injectors.
Refit
1.Lubricate new 'O' rings with castor oil and fit to
injectors.
2.Remove plugs from inlet manifolds.
3.Position injector harness to LH fuel rail and
secure with clips.
4.Position injectors and fuel rail to inlet manifolds.
5.Connect multiplugs to injectors.
6.Position injector cover - if fitted to RH fuel rail
and secure injector harness to protection cover
or to bosses on fuel rail with clips.
7.Fit bolts securing fuel rail to inlet manifolds and
tighten to 9 Nm (7 lbf.ft).
8. Up to 03MY: Position ignition coils to LH inlet
manifold.
9. 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).
10.Fit inlet manifold chamber.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.
11.Connect battery earth lead.
Fuel rail - KV6 - NAS
$% 19.60.04.99
Remove
1.Disconnect battery earth lead.
2.Remove inlet manifold chamber.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.
3.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
4.Using a 3/8" socket bar raise ancillary drive belt
tensioner and release drive belt from alternator
and PAS pump pulleys.
5.Remove nuts and bolts securing alternator.
6.Release alternator and place aside.

FUEL DELIVERY SYSTEM - PETROL
19-2-38 REPAIRS
15.Remove fuel rail and discard 'O' rings
CAUTION: Always fit plugs to open
connections to prevent contamination.
Refit
1.Lubricate new 'O' rings with castor oil and fit to
injectors.
2.Remove plugs from inlet manifolds.
3.Position injector harness to injector protection
cover - if fitted or to bosses on fuel rail fuel rail
and secure with clips.
4.Position injectors and fuel rail to inlet manifolds.
5.Connect multiplugs to injectors.
6.Fit and tighten 4 bolts securing fuel rail to inlet
manifold to 8 Nm (6 lbf.ft).
7. Up to 03MY: Position ignition coils to LH inlet
manifold.
8. 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).
9.Position alternator and secure with nuts and
bolts, tighten to 45 Nm (33 lbf.ft).
10.Using a 3/8" square drive socket bar, raise
ancillary drive belt tensioner and fit drive belt to
pulleys.
11.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
12.Fit inlet manifold chamber.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.
13.Connect battery earth lead.
Injector - KV6
$% 19.60.10
Remove
1.Disconnect battery earth lead.
2.Remove fuel rail.

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

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Fuel rail - KV6 - NAS.
3.Remove clip securing injector to fuel rail.
4.Remove injector from fuel rail, remove and
discard 'O' ring from injector.
CAUTION: Always fit plugs to open
connections to prevent contamination.
Refit
1.Clean injector and mating face in fuel rail.
2.Remove cap from new injector and fit to old
injector.
3.Lubricate new 'O' ring with castor oil and fit to
injector.
4.Fit injector to fuel rail and secure with 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.Connect battery earth lead.

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
30-3-12 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

STEERING
57-12 REPAIRS
Pump - steering - KV6
$% 57.20.14
Remove
1.Disconnect battery earth lead.
2.Remove engine mounting top arm.

+ ENGINE - K SERIES KV6, REPAIRS,
Arm assembly - engine mounting RH.
3.Loosen PAS pump pulley bolts.
4.Using a 3/8" socket bar, raise ancillary drive
belt tensioner and release drive belt from
alternator and PAS pump pulleys.
5.Position container to collect PAS fluid spillage.6.Release clip and disconnect fluid inlet hose
from PAS pump.
7.Remove banjo bolt securing fluid outlet hose to
PAS pump, release hose, remove and discard
sealing washers.
CAUTION: To prevent damage to
components, use two spanners when
loosening or tightening unions.
8.Remove bolt securing PAS outlet pipe support
bracket to cylinder head and move pipe aside.
9.Remove 3 bolts securing PAS pump pulley to
PAS pump and remove pulley.
CAUTION: Always fit plugs to open
connections to prevent contamination.

STEERING
REPAIRS 57-15
Pump - steering - Td4
$% 57.20.14
Remove
1.Disconnect battery earth lead.
2.Remove hydramount.

+ ENGINE - Td4, REPAIRS,
Hydramount - engine - RH.
3.Loosen 3 PAS pump pulley bolts.
4.Remove ancillary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - Td4.
5.Raise engine on hoist.
6.Remove bolts and remove PAS pump pulley.
7.Cover alternator to prevent PAS oil
contamination.
8.Place container beneath PAS pump, release
clip and remove feed hose to pump. Allow fluid
to drain.
CAUTION: Care must be taken to ensure
that oil or fluid does not enter or
contaminate the alternator.9.Remove banjo bolt securing fluid outlet hose to
PAS pump, release hose, remove and discard
sealing washers.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
10.Remove 4 bolts and remove PAS pump.
11.Remove 5 Torx bolts securing PAS pump to
mounting brackets. Collect mounting brackets.
Refit
1.Position PAS pump to mounting brackets, fit
and tighten Torx bolts to 25 Nm (18 lbf.ft).
2.Position pump to mounting, fit bolts and tighten
M8 bolts to 25 Nm (18 lbf.ft) and M6 bolts to 10
Nm (7.5 lbf.ft).
3.Using new sealing washers, fit PAS outlet hose
to pump and tighten banjo bolt to 25 Nm (18
lbf.ft).
4.Clean PAS pump and mating faces.
5.Fit inlet hose to PAS pump and secure with new
clip.
6.Fit PAS pump pulley to PAS pump and tighten
bolts to finger tight.
7.Fit ancillary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - Td4.
8.Tighten PAS pump pulley bolts to 10 Nm (7.5
lbf.ft).
9.Fit hydramount.

+ ENGINE - Td4, REPAIRS,
Hydramount - engine - RH.
10.Connect battery earth lead.

PANEL REPAIRS
REPAIRS 77-2-25
REPAIRS
Front bulkhead assembly
In this procedure, the crossmember gusset plates
are replaced in conjunction with the front bulkhead
assembly.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5.Remove front bumper armature.
6.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
7.Remove PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
8.Remove LH and RH headlamps.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
9.Release wiring to headlamps and position
aside.
10.Remove LH and RH engine bay shields.
11.Remove bumper valance LH and RH
attachment brackets.
12.Remove battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
13.Remove air intake hose.
14.Remove horn.

+ SECURITY, REPAIRS, Horn.
15.Remove windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
16.Remove bonnet lock.
17.Support bonnet in open position.
18.Remove bonnet stay. Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.

PANEL REPAIRS
77-2-26 REPAIRS
Refit
1.Fit bonnet stay.
2.Fit bonnet lock.
3.Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
4.Fit horn.

+ SECURITY, REPAIRS, Horn.
5.Fit air intake hose.
6.Fit battery. Do not connect earth lead.

+ CHARGING AND STARTING,
REPAIRS, Battery.
7.Fit bumper valance LH and RH attachment
brackets.
8.Fit LH and RH engine bay shields.
9.Fit LH and RH headlamps.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY. Secure headlamps
wiring.
10.Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
11.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
12.Fit front bumper armature.
13.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
14.Connect all ECUs.
15.Connect alternator.
16.Connect battery earth lead.

PANEL REPAIRS
REPAIRS 77-2-27
Bonnet locking platform
In this procedure the bonnet locking platform
reinforcement is also replaced in conjunction with the
bonnet locking platform.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
6.Remove both headlamp assemblies.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
7.Remove horn.

+ SECURITY, REPAIRS, Horn.
8.Remove battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
9.Remove air intake hose.
10.Remove bonnet lock.
11.Support bonnet in open position.
12.Remove bonnet stay.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Refit
1.Fit bonnet stay.
2.Fit bonnet lock.
3.Fit air intake hose.
4.Fit battery. Do not connect earth lead.

+ CHARGING AND STARTING,
REPAIRS, Battery.
5.Fit horn.

+ SECURITY, REPAIRS, Horn.
6.Fit both headlamp assemblies.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
7.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
8.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
9.Connect all ECUs.
10.Connect alternator.
11.Connect battery earth lead.