key LAND ROVER FREELANDER 2001 User Guide

ENGINE - K SERIES KV6
12-3-64 REPAIRS
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 hubs, crankshaft
gear, tensioner and water pump pulleys.
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.Fit hubs to camshaft gears and fit gears to
camshafts. Fit new bolts and tighten sufficiently
to allow gears to rotate without tipping.
3.Position timing belt to crankshaft gear.
NOTE: To prevent the timing belt from
disengaging from the crankshaft gear when
fitting, fit a suitable wedge between the belt and
oil pump belt guard.
4.Fit tool LRT-12-197 into each exhaust
camshaft in turn.5.Using assistance, rotate each exhaust
camshaft slightly and align timing marks on LH
and RH rear camshaft gears.
6.Remove tool LRT-12-197 from exhaust
camshaft.
7.Fit tools LRT-12-175 to LH and RH rear
camshaft gears.
8.Rotate both front inlet camshaft gears fully
clockwise as viewed from front of engine.
9.Using fingers only, fit timing belt to gears,
starting at the crankshaft gear and working in
an anti-clockwise direction, keeping the belt run
as taut as possible and turning the camshaft
gears only a minimum amount anti-clockwise to
fit timing belt.
CAUTION: Gears must not be rotated anti-
clockwise more than one tooth.
10.Position an Allen key in tensioner backplate
and hold tensioner pulley against timing belt.

ENGINE - K SERIES KV6
OVERHAUL 12-3-113
11.Position an Allen key in tensioner backplate
and hold tensioner pulley against timing belt.
12.With assistance, position timing belt tensioner,
fit new Patchlok bolts and tighten to 25 Nm (18
lbf.ft).
CAUTION: Ensure tensioner plunger is
contacting underside of tensioner
backplate.
13.Remove tools LRT-12-175 from rear timing belt
gears.
14.Fit tools LRT-12-196 to both front inlet
camshaft gears and into the end of each
exhaust camshaft.
CAUTION: Special tools must be fitted when
tightening or loosening gear retaining bolts,
otherwise damage to camshafts may occur.
15.Tighten front inlet camshaft gear bolts to:
lStage 1 - 27 Nm (20 lbf.ft)
lStage 2 - Further 90°
16.Remove tools LRT-12-196 from both inlet
camshaft gears and exhaust camshafts.17.Remove wedge from between drive belt and oil
pump belt guard.
18.Remove 1.5 mm diameter pin from tensioner.
19.Clean exhaust camshaft front cap seal
locations and fit new cap seals.
CAUTION: The sealing edge of the cap seal
and mating face must be clean and dry.
20.Position engine front mounting plate and
manoeuvre plate into position; fit bolts but do
not tighten at this stage.
21.Fit bolts securing IRD support bracket to front
mounting plate; do not tighten bolts at this
stage.
22.Tighten bolts in the sequence shown:
lM10 bolt - No.1 - 25 Nm (18 lbf.ft)
lM10 bolt - No. 5 - 45 Nm (33 lbf.ft)
lBolts Nos. 2, 3, 4, 6 and 7 - 85 Nm (63 lbf.ft)
23.Position engine lifting bracket, fit bolts securing
lifting bracket and front mounting plate to
cylinder block and RH cylinder head and
tighten to:
lM8 bolt - 25 Nm (18 lbf.ft)
lM10 bolts - 45 Nm (33 lbf.ft)
24.Fit rubber blanking plug around tensioner.
25.Clean end of dipstick tube.
26.Position dipstick tube to sump and cylinder
block, fit bolt and tighten to 9 Nm (7 lbf.ft).
27.Clean lower timing belt cover.
28.Position lower timing belt cover, fit and tighten
bolts to 9 Nm (7 lbf.ft).
29.Remove timing pin LRT-12-232.
30.Clean crankshaft pulley.
31.Fit crankshaft pulley to crankshaft gear and
ensure that the indent on pulley locates over
the lug on crankshaft gear.
32.Fit crankshaft pulley bolt and washer, position
LRT-12-161 with LRT-12-199 into crankshaft
pulley. Tighten pulley bolt to 160 Nm (118
lbf.ft).
33.Remove tools LRT-12-161 and LRT-12-199.
34.Clean ancillary drive belt tensioner.

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-5
REPAIRS
Selector housing
$% 44.15.04
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
3.Release inner cable from selector lever.
4.Remove 'C' clip securing outer cable to selector
housing.
5.If fitted, release mirror fold ECU and place
aside.
6.Disconnect shift interlock solenoid connector.
7.Disconnect multiplug from sport/manual switch.
8.If fitted, remove bolt and disconnect cable from
key interlock mechanism.9.Remove 6 nuts securing selector housing.
10.Remove selector housing.
11.Remove screw and remove mirror fold ECU
housing.
Refit
1.Position mirror fold ECU housing and secure
with screw.
2.Fit selector housing, fit nuts and tighten to 10
Nm (7.5 lbf.ft).
3.Connect key interlock mechanism inner cable.
Locate outer cable, fit clamp and clamp bolt but
do not tighten clamp bolt at this stage.
4.Connect multiplug to sport/manual switch.
5.Connect shift interlock solenoid connector.
6.Secure inner cable to selector lever.
7.Secure outer cable to selector housing with 'C'
clip.
8.Check key interlock cable adjustment.

+ STEERING, ADJUSTMENTS, Cable
- key interlock - adjust.
9.Fit front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
10.Remove stand(s) and lower vehicle.

STEERING
ADJUSTMENTS 57-1
STEERING ADJUST ME NTS
Power assisted steering (PAS) system -
bleed
$% 57.15.02
Check
1.Switch off engine.
2.Check power steering fluid, if aerated, wait until
fluid is free from bubbles then top-up reservoir
to 'UPPER' level mark.
3.Fit reservoir filler cap.
Adjust
1.Clean PAS fluid reservoir around filler cap and
fluid level indicators.
2.Remove filler cap from reservoir and fill
reservoir to 'UPPER' mark with Dexron II D
power steering fluid. Fluid must always be
present in reservoir while bleeding.
3.Start engine and allow to run at idle for 10
seconds. Stop engine.
4.Top-up steering fluid reservoir.
5.Start engine and turn steering fully to LH and
RH locks. Stop engine.
CAUTION: Do not hold steering at full lock
for longer than 10 seconds.
6.Top-up steering fluid reservoir.
7.Start and run engine for 2 minutes, turn
steering fully to RH and LH locks.
Cable - key interlock - adjust
$% 57.40.52
Check
1.Select position 'P'.
2.Remove key from starter switch.
3.Check that selector lever cannot be moved
from 'P' position.
4.Insert and turn key to position II.
5.Depress brake pedal and check that selector
lever can be moved from 'P' position, and key
cannot be removed from starter switch. Key
should only rotate back to a position between I
and 0.
Adjust
1.Select position 'P'.
2.Remove key from starter switch.
3.Remove front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
4.Loosen bolt securing cable clamp.
5.Pull cable away from interlock mechanism until
spring pressure is felt. Correct adjustment is
cable free play removed without compressing
spring. When correct tighten interlock cable
clamp screw to 6 Nm (4.5 lbf.ft).
6.Recheck cable operation.
7.Fit front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.

STEERING
57-16 REPAIRS
Nacelle - column
$% 57.40.29
Remove
1.Remove key from starter switch.
2.Carefully remove upper half of nacelle. Take
care when releasing clips from lower half of
nacelle.
3.Remove 2 screws securing lower nacelle to
steering column.
4.Lower steering column tilt lever.
5.Carefully remove cover from starter switch
being careful not to damage the passive coil.
6.Carefully pull lower half of nacelle from
retaining clip on column lockRefit
1.Ensure that the steering column tilt lever is
lowered.
2.Position lower half of nacelle and engage with
clip on column lock.
3.Raise column tilt lever.
4.Fit and tighten 2 screws securing lower half of
nacelle to steering column.
5.Fit cover to starter switch.
6.Fit upper half of nacelle and ensure that clips
engage with lower half.

STEERING
REPAIRS 57-17
Column lock & ignition/starter switch
assembly
$% 57.40.31
Remove
1.Disconnect battery earth lead.
2.Remove starter key from ignition lock.
3.Remove steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
column.
4.Disconnect multiplugs from ignition switch and
passive coil.
5.Remove passive coil.
6.Remove 2 screws and remove ignition switch.
7.Move rubber column cover aside to access
column lock bolts.
8.Mark both column lock bolts using a centre
punch.
9.Drill out both column lock bolts.10.Remove column lock saddle and remove
column lock.
11. Models with automatic transmission:
Loosen union and release key interlock cable
from column lock.
Refit
1. Models with automatic transmission: Align
key interlock cable to column lock and tighten
union to 4 Nm (3 lbf.ft).
2.Position lock to steering column assembly and
fit shear bolts. Do not tighten shear bolts at this
stage.
3.Insert starter key, check operation of steering
lock and that key turns freely.
4.Ensure correct operation of key interlock cable.
5.Remove starter key from column lock.
6.Tighten shear bolts fully and shear heads off.
7.Position ignition switch to column, fit and
tighten screws.
8.Fit passive coil.
9.Connect multiplugs to ignition switch and
passive coil.
10. Models with automatic transmission:
Ensure correct operation of microswitch.
11.Align column cover.
12.Fit steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
column.
13.Connect battery earth lead.

STEERING
57-18 REPAIRS
Cable - key interlock
$% 57.40.51
Remove
1.Disconnect battery earth lead.
2.Remove front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
3.Loosen bolt securing cable clamp.
4.Disconnect cable from interlock mechanism.
5.Remove key from starter switch.
6.Remove steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
column.
7.Remove bolt securing steering column height
adjuster lever and remove lever.
NOTE: Thread is left handed.
8.Remove nut securing height adjuster clamp
bolt and remove bolt.
9.Collect plastic stop.10.Loosen union and disconnect cable from
column lock.
11.Release cable from 2 retaining clips.
12.Note the cable routing, manoeuvre cable from
under heater and steering column bracket.
13.Remove cable.

STEERING
REPAIRS 57-19
Refit
1.Position cable, align to heater and steering
column bracket and secure in retaining clips.
2.Align key interlock cable to column lock and
tighten union to 4 Nm (3 lbf.ft).
3.Fit height adjuster clamp bolt and tighten nut to
10 Nm (7.5 lbf.ft). Ensure bolt and plastic stop
are correctly located in slot in column bracket.
4.Fit height adjuster lever and tighten bolt 12 Nm
(9 lbf.ft). Ensure lever is in the fully up position
before tightening bolt. Hold clamp bolt nut to
prevent nut rotation.
5.Connect cable to interlock mechanism.
6.Check key interlock cable adjustment.

+ STEERING, ADJUSTMENTS, Cable
- key interlock - adjust.
7.Fit steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
column.
8.Fit front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
9.Connect battery earth lead.
Column assembly - inner & outer
$% 57.41.01
Remove
1.Disconnect battery earth lead.
2.Remove steering column multi purpose switch.

+ LIGHTING, REPAIRS, Switch -
combined direction indicator/headlight/
horn.
3.Disconnect multiplugs from ignition switch and
passive coil.
4.Remove 2 screws securing steering column
aperture trim and remove trim.

STEERING
57-20 REPAIRS
5.Lower glove lid and remove fuse box cover.
6.Carefully cut 2 harness clips from LH side of
column and release harness.
7.Release 2 harness clips from RH side of
column and release harness.
8. Models with automatic transmission:
Release key interlock cable from column clip.9. Models with automatic transmission:
Loosen union and release key interlock cable
from column lock.
10. Models with automatic transmission:
Remove bolt securing steering column height
adjuster lever and remove lever.
11. Models with automatic transmission:
Remove nut securing height adjuster clamp
bolt and remove bolt.
12. Models with automatic transmission:
Release key interlock cable from steering
column.
13. Models with automatic transmission: Fit
clamp bolt and nut to retain support bracket in
position.

STEERING
REPAIRS 57-21
14.Remove pinch bolt securing steering column to
PAS rack pinion.
15.Remove bolt securing steering column to
fusebox support bracket.
16.Remove 2 nuts and 2 bolts securing steering
column to fascia support rail.
17.Collect snubber.
18.Release steering column from support bracket
and PAS rack pinion.
19.Remove steering column assembly.
20.Remove 2 cable ties from steering column.
21.Remove key interlock cable clip.22.Remove 2 screws securing ignition switch and
remove ignition switch.
23.Remove passive coil.
24.Position steering column assembly in a vice.
25.Centre punch or drill out steering lock shear
bolts.
CAUTION: If steering column is to be re-
used, take care not to deform or damage
column in vice.
26.Remove steering column lock.
CAUTION: Take care not to damage steering
lock body if the lock is to be refitted.