LAND ROVER FREELANDER 2001 Workshop Manual

ENGINE - K SERIES KV6
12-3-94 OVERHAUL
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. Up to 03MY:Position ignition coils to LH inlet
manifold.
20. 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).
21.Clean camshaft timing belt cover backplate
bolts and apply sealant, Part No. STC 50552 to
the first 3 threads.
22.Position backplate, fit and tighten bolts to 9 Nm
(7 lbf.ft).
23.Fit new camshaft timing belt.

+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.
24.Clean exhaust manifold and mating face on
cylinder head.
25.Fit new exhaust manifold gasket. Position
exhaust manifold, fit nuts and using sequence
shown, tighten to 45 Nm (33 lbf.ft).
26.Connect RH HO2S multiplug, secure multiplug
in coolant rail bracket.
Cylinder head - decarbonise
$% 12.29.19
Remove
1.Remove cylinder head gaskets.

+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - LH.

+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - RH.
Disassembly
1. LH Cylinder head: Remove 3 bolts securing
LH rear timing belt cover and remove cover.
2. RH Cylinder head: Remove 2 bolts securing
RH rear timing belt cover heat shield to cylinder
head.
3. RH Cylinder head:Remove 3 bolts securing
RH rear timing belt cover; remove cover.
M12 6880
M12 6694

ENGINE - K SERIES KV6
OVERHAUL 12-3-95
4.Position LRT-12-175 to rear camshaft gears as
illustrated, remove and discard bolts securing
gears to camshafts.
5.Remove rear camshaft gears, timing belt and
LRT-12-175 as an assembly.
6.Remove LRT-12-175 from camshaft gears and
remove timing belt from gears. Discard timing
belt.
7.Remove spark plugs.
8.Remove and discard exhaust camshaft cap
seal from cylinder head.
Note: RH cylinder head illustrated.9.Progressively loosen then remove 7 bolts
securing inlet manifold to cylinder head,
remove inlet manifold and discard gasket.
10.Remove 4 bolts securing camshaft front timing
belt cover backplate to cylinder head and
remove backplate.
Note: LH backplate illustrated.
11.Remove 2 bolts securing camshaft rear timing
belt cover backplate to cylinder head and
remove backplate.
Note: LH backplate illustrated.
M12 6882
M12 6883

ENGINE - K SERIES KV6
12-3-96 OVERHAUL
12.Check end-float of camshafts using a DTI.

+ GENERAL DATA, Engine - KV6
Petrol.
CAUTION: If camshaft end-float exceeds
limits given, repeat check with new
camshaft(s). If end-float is still excessive,
replace cylinder head and camshaft carrier
as an assembly.
13.Using sequence shown, progressively loosen
22 bolts securing camshaft carrier to cylinder
head until valve spring pressure is released
and remove bolts.
14.Remove camshaft carrier.15.Remove camshafts and discard oil seals.
Note: Inlet camshafts are colour coded orange,
exhaust camshafts
16.Using a stick magnet, remove 12 hydraulic
tappets from cylinder head.
CAUTION: Store hydraulic tappets in their
fitted order and store upright. Maintain
absolute cleanliness when handling
hydraulic tappets. Failure to observe these
precautions can result in engine failure.
17.Measure the outside diameter of hydraulic
tappets.

+ GENERAL DATA, Engine - KV6
Petrol.
Note: Measurement must be taken half-way
along tappet body.
18.Using LRT-12-034, and adapter LRT-12-034/1,
compress valve spring, remove 2 collets,
release valve spring and remove LRT-12-034.
19.Remove valve spring cap and valve spring.
20.Remove valve from cylinder head.

ENGINE - K SERIES KV6
OVERHAUL 12-3-97
21.Remove valve stem oil seal using LRT-12-071.
Discard stem seal.
22.Repeat procedure for remaining valves,
keeping components in their fitted order.
Inspect
1.Clean camshafts, bearing running surfaces in
carrier and cylinder head, carrier and cylinder
head mating faces.
2.Inspect camshafts and replace camshafts if
scored, pitted or excessively worn.
3.Position camshafts in cylinder head and place
Plastigauge across each journal.
CAUTION: Ensure camshafts are in their
correct fitted locations. Camshafts are
colour coded - Inlet - Orange; Exhaust -
Blue.
4.Refit camshaft carrier, fit bolts and using
sequence shown, tighten to 10 Nm (7.5 lbf.ft).
Do not rotate camshafts.5.Using the sequence shown, progressively
loosen and remove camshaft carrier bolts.
Release and remove camshaft carrier from
cylinder head.
6.Measure widest part of Plastigauge on each
journal.

+ GENERAL DATA, Engine - KV6
Petrol.
7.If clearance is excessive, fit new camshafts and
repeat check. If clearance is still excessive
renew cylinder head.
8.Remove all traces of Plastigauge using an oily
rag.
9.Clean sealing surfaces of cylinder heads.
Clean inlet and exhaust manifold mating faces.
CAUTION: Do not use a metal scraper.
10.Decarbonise combustion areas of cylinder
heads
11.Blow out all oilways and coolant passages.
12.Check cylinder head for damage, pay particular
attention to sealing faces.
M12 6889
LRT-12-071
mm.025.038.051.076
M12 6887

ENGINE - K SERIES KV6
12-3-98 OVERHAUL
13.Check cylinder head face for warping, across
centre and from corner to corner.

+ GENERAL DATA, Engine - KV6
Petrol.
14.Check cylinder head height.

+ GENERAL DATA, Engine - KV6
Petrol.
Note: Provided that cylinder head height is kept
within limits, cylinder heads may be refaced.
15.Check condition of valve springs and measure
free length of springs.

+ GENERAL DATA, Engine - KV6
Petrol.16.Remove carbon deposits from exhaust valve
guides using a 6 mm diameter reamer inserted
from combustion side of cylinder head.
17.Remove carbon from inlet valve guides, inlet
and exhaust valves and valve seat inserts.
Remove all loose carbon on completion.
18.Check and record existing valve stem
diameters 'A', replace any valve with stem
diameter less than specified.

+ GENERAL DATA, Engine - KV6
Petrol.
19.Check inlet and exhaust valve to guide
clearances 'B' using the following procedures.

ENGINE - K SERIES KV6
OVERHAUL 12-3-99
20.Insert each valve into its respective guide.
21.Extend valve head 15 mm (0.6 in) out of guide
and position DTI gauge to rear of valve head.
22.Move valve towards front of cylinder head and
zero gauge ensuring that stylus of gauge
remains in contact with valve head.
23.Move valve towards rear of cylinder head,
record gauge reading obtained to give valve
stem to guide clearance 'B'.

+ GENERAL DATA, Engine - KV6
Petrol.
24.Remove valves ensuring they are retained in
their fitted order.
25.Renew valves and/or guides as necessary.
26.To replace valve guides support cylinder head
face down on wooden blocks.
27.Position LRT-12-519-3 in tappet bore and drift
out valve guide using LRT-12-519-1.
CAUTION: Retain guides in their fitted
order.28.Identify type of valve guide fitted: 'A' - Standard
production 'B' - Service replacement.
CAUTION: Standard production valve
guides A must be replaced with service
replacement guides B.
29.Locate valve guide in valve guide bore with
identification groove towards valve seat and
position depth gauge LRT-12-519-2 onto valve
guide.
CAUTION: Cylinder head and valve guides
must be at room temperature when fitting
guides.
30.Position nylon guide LRT-12-519-3 in cylinder
head, press guide into bore using driver LRT-
12-519-1 until depth gauge contacts cylinder
head.
M12 6890
LRT-12-519-1
LRT-12-519-3
M12 6892
LRT-12-519-2
LRT-12-519-1
LRT-12-519-3

ENGINE - K SERIES KV6
12-3-100 OVERHAUL
31.Check that fitted height of valve guide, 'A', is
6.00 mm (0.24 in).
32.Check condition of valve seats and existing
valves that are to be re-used.
33.Renew valve seat inserts as necessary.
CAUTION: Do not damage counterbore
when removing insert.
34.Cool replacement valve seat inserts using
liquid nitrogen and press into cylinder head in
one continuous operation.
CAUTION: Do not heat cylinder head.
Inserts must not stand proud of combustion
face on completion of cutting operation.
35.Cut valve seats using a suitable pilot and the
following cutters:
l15° - To cut first angle
l45° - Make final cut and remove any burrs
l60° - To narrow seat and obtain correct
valve seat width
36.Check valve seat width and face angle:
lSeat width - 'A' - Inlet = 1.2 mm (0.05 in);
Exhaust = 1.6 mm (0.06 in)
lValve face angle - 'B' - Inlet and exhaust =
45°
37.Lap each valve to its seat using grinding paste.38.Apply Prussian Blue to valve seat, insert valve
and press it into position several times without
rotating. Remove and check valve for even and
central seating: seating position shown by
Prussian Blue should be in the centre of valve
face: a: High towards stem, increase 60° cut
and restore seat width. b: Low towards edge,
increase 45° cut and restore seat width. Lap
and recheck valve seating.
39.Check valve stem fitted height - 'A'.

+ GENERAL DATA, Engine - KV6
Petrol.
CAUTION: If valve stem fitted height is
above service limit, fit new valve and re-
check. If still over limit, renew valve seat
insert.
40.Clean valve springs and lubricate valves.
Reassembly
1.Lubricate new valve stem oil seals with clean
engine oil.
2.Using tool LRT-12-071 fit new valve stem oil
seals.
3.Fit valves.
M12 7894
A

ENGINE - K SERIES KV6
OVERHAUL 12-3-101
4.Fit spring and spring cap.
5.Position LRT-12-034 and adapter LRT-12-
034/1to spring cap and compress valve spring.
6.Fit collets.
7.Release valve spring and remove tool LRT-12-
034.
8.Using a wooden dowel and mallet, lightly tap
top of each valve two or three times to seat
valves and collets.
9.Thoroughly clean and lubricate hydraulic
tappets with clean engine oil. Fit hydraulic
tappets to original bores in cylinder head.
10.Ensure that mating faces of camshaft carrier
and cylinder head are clean and dry.
11.Lubricate camshafts and bearing journals with
clean engine oil.
12.Position camshafts in cylinder head with rear
timing gear drive slots in each camshaft facing
towards the centre as shown.
CAUTION: Ensure camshafts are in their
correct fitted locations. Camshafts are
colour coded - Inlet - Orange; Exhaust -
Blue.13.Apply continuous thin beads of sealant, Part
No. STC 4600, to paths on camshaft carrier as
shown. Spread sealant to an even film using a
roller.
CAUTION: To avoid contamination,
assembly should be completed immediately
after application of sealant.
14.Position camshaft carrier, fit and progressively
tighten bolts in the sequence shown to 10 Nm
(7.5 lbf.ft).

ENGINE - K SERIES KV6
12-3-102 OVERHAUL
15.Noting that the front camshaft oil seals are
black in colour and the rear oil seals are red, fit
new camshaft oil seals using LRT-12-203 and
LRT 12-148A
CAUTION: Oil seals must be fitted dry. Do
not use tool LRT-12-148 for fitting seals.
16.Clean camshaft timing belt cover backplate
bolts and apply sealant, Part No. STC 50552 to
the first 3 threads.
17.Position camshaft timing belt rear cover
backplates to cylinder head, fit and tighten bolts
to 9 Nm (7.5 lbf.ft).
18.Fit spark plugs.
19.Clean rear camshaft gears and mating faces on
camshafts.
CAUTION: If sintered gears have been
subjected to prolonged oil contamination,
they must be soaked in solvent 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 timing belts.20.Place gears inverted on a flat surface, with the
locating lugs on the gears positioned as
illustrated.
21.Keeping the timing marks aligned, position
timing belt onto gears.
22.Position LRT-12-195 between the gears, turn
centre nut sufficiently to spread drive belt.
23.Invert gears and timing belt and position LRT-
12-175 to camshaft gears.
24.Check that locating lugs are still aligned and
remove LRT-12-195 from between camshaft
gears.

ENGINE - K SERIES KV6
OVERHAUL 12-3-103
25.Fit LRT-12-198 alignment pins into the end of
each camshaft.
26.Position timing belt and gears over LRT-12-198
and locate gears onto camshafts.
27.Position LRT-12-197 into the front end of the
exhaust camshaft.
28.With assistance, using a 30 mm socket on LRT-
12-197, turn the exhaust camshaft sufficiently
to align camshaft gears to the drive slots in
each camshaft.29.Remove LRT-12-198 alignment pins and fit
new camshaft gear retaining bolts.
30.Tighten camshaft gear bolts to:
lStage 1 - 27 Nm (20 lbf.ft)
lStage 2 - Further 90°
31.Remove LRT-12-175 from camshaft gears.
32.Remove LRT-12-197 from front end of exhaust
camshaft.
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.
33.Fit timing belt rear cover and tighten bolts to 9
Nm (7 lbf.ft).
Refit
1.Fit cylinder head gaskets.

+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - LH.

+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - RH.