ignition LAND ROVER FREELANDER 2001 User Guide

TORQUE WRENCH SETTINGS
06-13
Fuel delivery system – Petrol
1 Tighten in sequence using the procedure defined in 'Repairs' section.

+ ENGINE MANAGEMENT SYSTEM - SIEMENS, REPAIRS, Sensor - combined - manifold absolute
pressure/Intake air temperature (MAP/IAT).
TORQUE DESCRIPTION METRIC IMPERIAL
Air cleaner to battery tray bolts 9 Nm 7 lbf.ft
Fuel filler neck to body nuts and bolt 9 Nm 7 lbf.ft
Fuel pump/sender unit to tank locking ring 35 Nm 26 lbf.ft
Fuel rail to inlet manifold bolt 8 Nm 6 lbf.ft
Fuel tank to body bolts 40 Nm 29 lbf.ft
Heated Oxygen (HO
2S) Sensor 40 Nm 29 lbf.ft
Ignition coils to LH inlet manifold nuts and bolts - KV6 - Up to 03 Model Year 9 Nm 7 lbf.ft
Inertia (fuel cut-off) switch 2 Nm 1.5 lbf.ft
Intake Air Control Valve (IACV) to throttle body Allen screws 6 Nm 4.5 lbf.ft
Subframe to body bolts 190 Nm 140 lbf.ft
Throttle housing to inlet manifold bolts
1 (K1.8)
⇒1st. stage4 Nm 3 lbf.ft
⇒2nd. stage9 Nm 7 lbf.ft
Throttle body to inlet manifold chamber Torx screws (KV6) 8 Nm 6 lbf.ft
Throttle actuator support bracket to throttle body Torx screws (vehicles with cruise
control only)9 Nm 7 lbf.ft
Throttle position sensor to housing Torx screws 1.5 Nm 1.1 lbf.ft
VIS motor to inlet manifold chamber screws (KV6 only) 8 Nm 6 lbf.ft

LIFTING AND TOWING
08-2
Raising the front of a vehicle
Position the cup of the hydraulic arm under the
centre of the front body crossmember assembly.
Use jack to raise front road wheels to enable safety
stands to be installed under the front end of each
longitudinal member.
Carefully lower jack until vehicle sits securely on
safety stands.
Before working on the underside of a vehicle re-
check the stability of the vehicle on the stands.
Use the reverse procedure when removing a vehicle
from stands.
NOTE: For some repair operations it may be
necessary to use a jack to support the engine under
the sump. In this case, a block of wood should be
used on the jack to protect the sump.
Raising the rear of a vehicle
Position cup of hydraulic arm under the centre of the
rear subframe crossmember at the position
identified by the embossed arrows.
Use jack to raise rear road wheels to enable safety
stands to be installed under the rear ends of the
body longitudinal members.
Carefully lower jack until vehicle sits securely on
safety stands.
Before working on the underside of a vehicle, re-
check the stability of the vehicle on the stands.
Use the reverse procedure when removing a vehicle
from stands.
Wheel-free lift
Locate the lifting pads under the ends of the body
longitudinal members. Raise the ramp to support the
weight of the vehicle, ensure the vehicle is secure on
the lifting pads, then raise the ramp to the required
height.
Towing
General
The vehicle has permanent four wheel drive. The
following instructions must be adhered to:
Towing the vehicle on all four wheels with driver
operating steering and brakes
lTurn ignition key to position '1' to release
steering lock and then to position 'II' to enable
the brake lights, wipers and direction indicators
to be operated, if necessary.
l Select neutral in gearbox and ensure HDC (hill
descent control) is deselected.
lSecure tow rope, chain or cable to towing eye.
lRelease the parking brake.
CAUTION: The brake servo and power assisted
steering system will not be functional without the
engine running. Greater pedal pressure will be
required to apply the brakes and the steering
system will require greater effort to turn the front
road wheels. The vehicle tow connection should
only be used under normal road conditions,
'snatch' recovery should be avoided.
Suspended tow by breakdown vehicle
Mark propeller shaft drive flanges and mating flanges
with identification lines to enable the propeller shaft
to be refitted in its original position.
Remove the propeller shaft fixings then remove the
shaft from the vehicle.
CAUTION: To prevent vehicle damage, rear
propeller shaft MUST BE removed.

LIFTING AND TOWING
08-3
If the front of the vehicle is to be trailed, turn ignition
key to position 'I' to release steering lock.
WARNING: Do not turn the starter switch to
position '0' or remove the ignition key while the
vehicle is being towed.
CAUTION: If it is considered unsafe to turn the
starter switch to position '1' due to accident
damage or an electrical fault; disconnect the
battery before turning the ignition switch.
CAUTION: The steering wheel and/or linkage
must be secured in a straight ahead position. DO
NOT use the steering lock mechanism for this
purpose.
CAUTION: Under no circumstances should the
vehicle be towed or recovered by means of
lashing to the rear subframe. Serious damage to
the subframe and body could result.
CAUTION: Only use the rear towing eye for
towing another vehicle.
Towing eyes
The towing eyes at the front and rear of the vehicle
are designed for vehicle recovery purposes only and
must not be used to tow a trailer or caravan.
Front and rear towing eyes
A single towing eye is provided in the front spoiler.
Only use when the vehicle is to be towed with all four
wheels on the ground.
A single towing eye is provided in the rear RH spoiler.
Only use when towing another vehicle.Transporting the vehicle by trailer
Lashing rings are provided at the front and rear of the
body to facilitate the securing of the vehicle to a
trailer or other means of transportation.
CAUTION: Underbody components must not be
used as lashing points. The lashing rings must
not be used for towing.
Install the vehicle on trailer and apply the parking
brake. Select neutral.
Lashing eyes
Lashing rings are provided at the front and rear of the
vehicle for use when transporting by trailer. DO NOT
use lashing eyes for towing purposes.
Front lashing eye
Rear lashing eyes

LIFTING AND TOWING
08-4
Emergency starting
WARNING: Battery fluid (electrolyte) contains
sulphuric acid. It may cause severe burns if it
gets on your skin or in your eyes. Wear
protective clothing and a face shield.
If electrolyte gets on your skin or clothes,
immediately rinse it off with water.
If electrolyte gets in your eyes, immediately flush
eyes with water for at least 15 minutes and seek
medical help.
To Jump Start - Negative Ground Battery
Position vehicles so that jump leads will reach,
ensuring that vehicles DO NOT TOUCH,
alternatively a fully charged slave battery may be
positioned on the floor adjacent to the vehicle.
Ensure that:
lthe ignition and all electrical accessories are
switched off
lthe parking brake is applied and neutral is
selected on gearbox
Connect the jump leads as follows:
WARNING: Making final cable connection could
cause an electrical arc, which if made near
battery could cause an explosion.
aConnect one end of first jumper cable to
positive (+) terminal of booster battery.
bConnect other end of first jumper cable to
positive (+) terminal of discharged battery.
cConnect one end of second jumper cable to
negative terminal of booster battery.
dConnect other end of second jumper cable to a
good earth point on the engine, NOT TO
NEGATIVE TERMINAL OF DISCHARGED
BATTERY.
CAUTION: Keep jumper leads away from moving
parts, pulleys, drive belts and fan blade
assembly.If the booster battery is installed in another vehicle,
start engine and allow to idle.
Start engine of vehicle with discharged battery,
following starting procedure in Owners' Handbook.
CAUTION: If vehicle fails to start within a
maximum time of 12 seconds, switch ignition off
and investigate cause. Failure to follow this
instruction could result in irreparable damage to
catalyst.
To disconnect:
l Remove negative (-) jumper cable from the
engine and then terminal of booster battery.
lRemove positive (+) jumper cable from positive
terminals of booster battery and discharged
battery.

MAINTENANCE
10-4 MAINTENANCE
Seats and Seat Belts
Check
1.Check seat frames are secured to floor and
show no signs of movement.
2.Check operation of seat slide and tilt
mechanisms, ensuring there is no excessive
play between seat cushion and seat back.
3.Check tightness of accessible seat fixings.
4.Fully extract seat belt and allow it to return
under its own recoil mechanism.
5.Check entire length of seat belt webbing for
signs of fraying or damage. Repeat for all belts.
6.Check security of seat belt upper mountings.
7.Check for correct operation of seat belt height
adjusters.
8.Check security of seat belt buckle mountings.
9.Connect each belt to the correct buckle, check
seat belt buckle and tongue are secure.
Release seat belt buckle and check for correct
operation.
10.Check tightness of accessible seat belt
mountings.
Lamps, Horns and Warning Indicators
Check
1.Switch on side, head and tail lights and check
operation.
2.Check headlamp dim/dip operation.
3.Check headlamp levelling operation.
4.Check turn signals and hazard warning lights
operation.
5.Press brake pedal and check operation of
brake lights.
6.Check all exterior lamp lenses for clarity and
condition. Pay particular attention to head lamp
lenses for signs of stone chips or damage.
7.Check horn for loud clear sound.
8.Check operation of all instrument pack warning
and indicator lights.
9.Check for correct operation of interior courtesy
lights.
10.Switch on headlamps (with ignition switch at 'O'
position) and check light reminder warning
operates when door is opened.

ENGINE - K SERIES KV6
REPAIRS 12-3-13
Cylinder head gasket - LH
$% 12.29.02
Remove
1.Disconnect battery earth lead.
2.Drain cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
3.Remove inlet manifold chamber.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.
4.Remove LH exhaust manifold gasket.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket - exhaust
manifold - LH - Non NAS.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket(s) -
exhaust manifold - LH - NAS.
5.Remove camshaft timing belt.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
6.Remove 4 bolts securing LH front camshaft
timing belt cover backplate to cylinder head;
remove backplate.
7.Remove LH camshaft cover gasket.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - LH - Up to 03MY.8.Remove 3 nuts and 3 bolts securing ignition
coils to LH inlet manifold and release coil earth
lead, if fitted.
9.Remove ignition coils and position aside, if
fitted.
10.Release clip and disconnect coolant bleed
hose from inlet manifold and move hose aside.
11.Depress locking collar and release breather
hose from LH inlet manifold.

ENGINE - K SERIES KV6
REPAIRS 12-3-15
Refit
1.Clean cylinder head mating 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.10.Tighten cylinder head bolts progressively in the
sequence shown to :
lStage 1 - 25 Nm (18 lbf.ft)
lStage 2 - Tighten in the same sequence to
25 Nm (18 lbf.ft)
lStage 3 -Tighten in the same sequence to
25 Nm (18 lbf.ft)
lStage 4 - Using an angle torque gauge,
tighten bolts in the 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.Position CMP sensor bracket, fit and tighten
bolt to 9 Nm (7 lbf.ft).
19.Connect CMP sensor multiplug and secure to
bracket.
20.Connect breather hose to LH inlet manifold.
21.Connect coolant bleed hose to inlet manifold
and secure with clip.
22.Position ignition coils to LH inlet manifold.
23.Position earth lead, fit nuts and bolts securing
ignition coils to LH inlet manifold and tighten to
9 Nm (7 lbf.ft).
24.Position ht lead guide bracket, fit and tighten
special bolt.
25.Connect ht leads to spark plugs and secure ht
leads in guide clips.
26.Clean camshaft timing belt cover backplate
bolts and apply sealant, Part No. STC 50552 to
the first 3 threads.

ENGINE - K SERIES KV6
REPAIRS 12-3-19
10.Tighten cylinder head bolts progressively in the
sequence illustrated to:
lStage 1 - 25 Nm (18 lbf.ft)
lStage 2 - Tighten in the same sequence to
25 Nm (18 lbf.ft)
lStage 3 -Tighten in the same sequence to
25 Nm (18 lbf.ft)
lStage 4 - Using an angle torque gauge,
tighten bolts in the same sequence a 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.
16.Position injector protection cover - if fitted to RH
fuel rail; 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 hoses to RH camshaft cover
and 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.Connect multiplugs to plug top coils and secure
with locking clips.
23.Clean camshaft timing belt cover backplate
bolts and apply sealant, Part No. STC 50552 to
the first 3 threads.
24.Position backplate, fit and tighten bolts to 9 Nm
(7 lbf.ft).25.Fit camshaft timing belt.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
26.Fit RH exhaust manifold gasket.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket - exhaust
manifold - RH - Non NAS.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket(s) -
exhaust manifold - RH - KV6 - NAS.
27.Fit inlet manifold chamber.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.
28.Fill cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
29.Check engine oil level and top-up if necessary.

+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.

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