engine LAND ROVER FREELANDER 2001 Workshop Manual

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-17
Refit
1.Clean remains of old sealant from mating faces
of end cover and IRD main case.
2.Apply a narrow bead of sealant, Part No. STC
4600to mating face of end cover.
3.Fit end cover to IRD and tighten bolts
progressively to 30 Nm (22 lbf.ft).
4.Fit IRD support bracket and tighten bolts
sufficiently only to pull mating faces together.
5.Final tighten all bolts in following sequence:
l5 bolts securing support bracket to IRD 50
Nm (37 lbf.ft)
l2 bolts securing support bracket to engine
front mounting bracket 50 Nm (37 lbf.ft)
l3 bolts securing support bracket to sump 88
Nm (65 lbf.ft).
6.Fit engine lower steady.

+ ENGINE - K SERIES KV6, REPAIRS,
Engine steady - lower.7. Non NAS models: Fit heat shield.
8. Non NAS models: Fit nut securing heat shield
to IRD and tighten to 45 Nm (33 lbf.ft).
9. Non NAS models: Fit bolts securing manifold
heat shield to IRD support bracket and tighten
to 9 Nm (7 lbf.ft).
10. Non NAS models: Fit nut securing heat shield
to IRD pinion housing and tighten to 25 Nm (18
lbf.ft).
11.Fit drive shaft RH seal.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - driveshaft - RH.
12.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
13. NAS models: Fit RH catalytic converter.

+ EMISSION CONTROL, REPAIRS,
Catalytic converter - RH - KV6 - NAS.

INTERMEDIATE REDUCTION DRIVE
41-18 REPAIRS
Gasket - end cover - IRD housing - K1.8
$% 41.27.05
Remove
1.Drain fluid from IRD.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
2.Remove drive shaft RH seal.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - driveshaft - RH.
3.Remove bolt securing engine lower steady to
beam.
4.Remove bolt securing engine lower steady to
bracket on sump.
5.Remove engine lower steady.
6.Remove 3 bolts securing lower engine steady
bracket to sump and remove bracket.7.Remove upper bolt securing IRD support
bracket to cylinder block.
8.Remove 5 bolts securing support bracket to
IRD.
9.Remove 3 bolts securing IRD support bracket
to sump and remove bracket.
10.Remove 8 bolts securing end cover to main
case of IRD.
11.Remove end cover.
12.Remove bolt securing engine lower steady to
bracket on sump.
M12 7144
M12 7165
M12 7166

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-19
Refit
1.Clean remains of old sealant from mating faces
of end cover and IRD main case.
2.Apply a narrow bead of sealant, Part No. STC
4600to mating face of end cover.
3.Fit end cover to IRD and tighten bolts
progressively to 30 Nm (22 lbf.ft).
4.Fit IRD support bracket and tighten bolts
sufficiently only to pull mating faces together.
5.Final tighten bolts securing IRD support bracket
in following sequence:
l5 bolts securing IRD support bracket to IRD
50 Nm (37 lbf.ft),
l1 bolt securing support bracket to cylinder
block 45 Nm (33 lbf.ft),
l3 bolts securing support bracket to sump 88
Nm (65 lbf.ft).
6.Position engine lower steady bracket to sump,
fit and tighten bolts to 100 Nm (74 lbf.ft).
7.Fit engine lower steady, fit bolts and tighten to
80 Nm (59 lbf.ft).
8.
9.Fit drive shaft RH seal.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - driveshaft - RH.
10.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
Seals - primary gear shaft
$% 41.29.02
Remove
1.Remove IRD.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - K1.8.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - Td4.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.
2.Remove 8 bolts securing end cover to main
case of IRD.
3.Remove end cover.
4.Remove intermediate shaft and differential
from primary shaft.

AUTOMATIC GEARBOX - JATCO
ADJUSTMENTS 44-1
AUTOMATIC GE ARBOX - JATCO ADJUST ME NTS
Inhibitor switch - adjust
$% 44.15.18
Adjust
1.Set gear selector lever to 'N' position.
2.Loosen 2 bolts securing inhibitor switch to
gearbox casing.
3.Fit tool LRT-44-018 to selector lever on
gearbox, rotate inhibitor switch sufficient to
insert tool alignment pin through tool lever into
inhibitor switch.
4.Tighten inhibitor switch bolts to 3 Nm (2.2
lbf.ft)and remove LRT-44-018.
5.Check that the engine will start in 'P' and 'N'
positions and is inhibited when drive positions
are selected.
M44 1645A
LRT-44-018

AUTOMATIC GEARBOX - JATCO
ADJUSTMENTS 44-3
Selector cable - adjust
$% 44.30.04
Adjust
1.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
2.Loosen trunnion nut securing inner cable to
selector lever.
3.Move gear change lever into 'P' position.
4.Move selector lever on gearbox fully clockwise
to engage 'P' position.
5.Pull inner cable as far forward as possible, then
release. This will remove any backlash from the
cable.
6.Tighten trunnion nut to 6 Nm (4 lbf.ft).
7.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
8.Move selector lever through its working arc;
from 'P' to '2' and back to 'P', checking that all
gear positions are correctly selected.
9.Check that the engine will start in 'P' and 'N'
positions and is inhibited when drive positions
are selected.
M44 1640

AUTOMATIC GEARBOX - JATCO
44-12 REPAIRS
Gearbox - KV6 - with engine and gearbox
removed
$% 44.20.01.99
Remove
1.Release HO2S multiplug from support bracket
on LH camshaft cover, disconnect multiplug.
2.Remove 4 nuts securing LH exhaust manifold
to cylinder head.
3.Remove exhaust manifold, remove and discard
gasket.4.Remove nut securing manifold heat shield to
IRD unit.
5.Remove nut securing heat shield to IRD pinion
housing.
6.Remove 2 bolts securing heat shield and
remove heat shield.
7.Disconnect breather hose from IRD housing.
8.Release clips and disconnect coolant hoses
from IRD.

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-13
9.Remove bolt securing engine lower steady to
IRD support bracket.
10.Remove lower engine steady noting that 'TOP'
mark on engine steady faces uppermost.
11.Remove 3 bolts securing IRD support bracket
to sump.
12.Remove 2 bolts securing IRD support bracket
to engine front mounting plate.13.Remove 5 bolts securing support bracket to
IRD.
14.Remove support bracket.
15.Remove 4 bolts securing IRD.
16.With assistance, release IRD from gearbox and
remove.
17.Remove and discard 'O' ring from IRD.
M41 7698

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-15
26.Disconnect 2 fluid cooler hose unions and
discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
27.Release 2 clips and disconnect coolant hoses
from fluid cooler.
28.Remove bolts securing fluid cooler.
29.Remove fluid cooler.30.Remove bolt securing CKP sensor to gearbox,
release sensor and position aside.
31.Remove nut and bolt, adjacent to CKP sensor,
securing gearbox to engine.
32.Fit suitable lifting brackets to gearbox and
secure with nuts and bolts.
33.Connect lifting equipment to brackets.
34.Remove 2 bolts securing gearbox to engine.
M44 1639
M44 1665
M44 1651

AUTOMATIC GEARBOX - JATCO
44-16 REPAIRS
35.Remove 2 top bolts securing gearbox to
engine.
36.Release gearbox from 2 dowels.
37.Remove gearbox assembly.
38.Fit converter retaining plate and secure with
bolts.Refit
1.Remove torque converter retaining plate.
2.Ensure converter is fully located in oil pump
drive by checking depth 'A' as illustrated. Depth
A = 4 mm.
3.Clean gearbox to engine mating faces, dowels
and dowel holes.
4.Fit gearbox assembly.
5.Fit bolts securing gearbox and tighten to 85 Nm
(63 lbf.ft).
6.Disconnect lifting equipment.
7.Clean CKP sensor and mating face.
8.Fit CKP sensor, fit bolt and tighten to 9 Nm (7
lbf.ft).
9.Position fluid cooler, tighten M12 bolts to 85 Nm
(63 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).
10.Connect hoses to fluid cooler.
11.Clean fluid cooler unions.
12.Lubricate new 'O' rings with clean transmission
fluid and fit 'O' rings to fluid cooler hoses.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
13.Connect fluid cooler hoses to gearbox and
tighten unions to 18 Nm (13 lbf.ft).
14.Clean starter motor mating faces.
15.Position starter motor to gearbox, align CKP
sensor multiplug bracket, fit and tighten bolts to
45 Nm (33 lbf.ft).
16.Using gearbox bracket bolts, secure LRT-44-
026 lifting bracket to gearbox.
17.Position IRD cooling hose retainer, fit bolt and
tighten to 25 Nm (18 lbf.ft).
18.Align marks on drive plate to torque converter.
19.Fit bolts securing drive plate to torque converter
and tighten bolts to 45 Nm (33 lbf.ft).
20.Clean torque converter access plate.
M44 1689
A
M44 1668

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-17
21.Position access plate, fit bolts and tighten to 9
Nm (7 lbf.ft).
22.Clean mating faces of IRD and gearbox.
23.Lubricate and fit new 'O' ring.
24.With assistance, fit IRD.
25.Fit bolts securing IRD to gearbox and tighten
sufficiently only to pull mating faces of IRD and
gearbox together at this stage.
26.Fit IRD support bracket and tighten bolts
sufficiently only to pull mating faces together.
27.Final tighten bolts securing IRD to gearbox to
80 Nm (59 lbf.ft).
28.Final tighten bolts securing IRD support
bracket in following sequence:5 bolts securing
support bracket to IRD 50 Nm (37 lbf.ft), 2 bolts
securing support bracket to engine front
mounting bracket 50 Nm (37 lbf.ft), 3 bolts
securing support bracket to sump 45 Nm (33
lbf.ft).
29.Position lower engine steady, 'TOP' mark
uppermost. Fit bolt but do not tighten at this
stage.
30.Connect coolant hoses and secure with clips.
31.Connect breather hose to IRD housing.
32.Fit manifold heat shield and fit nut securing
heat shield to pinion housing finger tight.
33.Fit bolts securing manifold heat shield to IRD
support bracket and tighten to 9 Nm (7 lbf.ft).
34.Fit nut securing heat shield to IRD and tighten
to 45 Nm (33 lbf.ft).
35.Final tighten nut securing manifold heat shield
to IRD pinion housing to 25 Nm (18 lbf.ft).
36.Clean exhaust manifold and mating face on
cylinder head.
37.Fit exhaust manifold gasket.
38.Position exhaust manifold, fit nuts and
progressively tighten, from centre outwards to
45 Nm (33 lbf.ft).
39.Connect HO2S multiplug and secure to support
bracket.
Gearbox - KV6
$% 44.20.02.99
Remove
1.Tie bonnet back in upright position.
2.Disconnect battery earth lead.
3.Remove engine acoustic cover.

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

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.
5.Loosen selector cable trunnion nut.
6.Release clip securing selector cable to gearbox
bracket, remove selector cable and collect
trunnion from selector lever.
7.Remove 3 screws securing LH splash shield
and remove shield.