LAND ROVER FREELANDER 2001 Workshop Manual

ENGINE - K SERIES KV6
12-3-104 OVERHAUL
Oil pump - Overhaul
$% 12.60.32
Remove
1.Remove oil pump gasket.

+ ENGINE - K SERIES KV6, REPAIRS,
Gasket - oil pump.
Disassembly
1.Remove 4 Torx screws securing cover plate to
oil pump body.
CAUTION: Do not allow cover to separate
from pump body.
2.Invert oil pump.
3.Carefully remove cover plate from oil pump
body taking care to ensure that rotors are
retained in pump body.
Note: Cover plate is dowel located.4.Remove and discard cover plate sealing ring.
5.Make suitable alignment marks between inner
and outer rotors and pump body.
6.Remove inner and outer rotors.
7.Clean inner and outer rotors and rotor housing.
8.Fit inner and outer rotors ensuring that
reference marks are aligned.
Inspect
1.Check rotor clearances:
lOuter rotor to body = 0.13 - 0.23 mm
(0.0051 - 0.0091 in)
lInner rotor tip = 0.05 - 0.13 mm (0.002 -
0.005 in)
lInner and outer rotor end-float = 0.04 - 0.09
mm (0.0016 - 0.0035 in)
2.Renew oil pump as an assembly if clearances
are excessive.

ENGINE - K SERIES KV6
OVERHAUL 12-3-105
3.Remove oil pressure relief valve plug.
Note: If a hexagonal plug and sealing washer
are fitted, discard washer.
4.Remove spring and valve.
5.Check that valve and bore are free from scoring
and corrosion.
Note: Light corrosion may be removed using
grade 600 emery cloth soaked in engine oil.
6.Check free length of spring.

+ GENERAL DATA, Engine - KV6
Petrol.
7.Check that valve slides freely in bore.
CAUTION: If valve is scored, renew relief
valve as an assembly. If valve bore is
scored, renew oil pump as an assembly.Reassembly
1.Clean cover plate and mating face of cylinder
block; ensure bolt holes are clean and dry.
2.Clean running surface on crankshaft.
3.Remove all traces of sealant from relief valve
plug, Torx screws and tapped holes in pump
body.
CAUTION: Do not use a tap.
4.Lubricate relief valve, spring and bore with
clean engine oil.
5.Fit relief valve and spring.
6.If a hexagonal plug and sealing washer were
fitted, fit new sealing washer to plug.
7.Apply sealant, Part No. STC 50552 to plug
threads; fit plug and tighten to 25 Nm (18 lbf.ft).
8.Lubricate pump rotors and recess with clean
engine oil.
9.Fit inner and outer rotors ensuring that
identification mark on outer rotor is facing
outwards and that reference marks are aligned.
10.Lubricate new cover plate sealing ring with
clean engine oil.
11.Fit cover plate seal and cover plate.
12.Apply sealant, Part No. STC 50552 to threads
of Torx screws, fit and tighten screws.
13.Check that pump rotates freely.
Refit
1.Fit oil pump gasket.

+ ENGINE - K SERIES KV6, REPAIRS,
Gasket - oil pump.

ENGINE - K SERIES KV6
12-3-106 OVERHAUL
Sump - engine oil
$% 12.60.38.01
Remove
1.Drain engine oil.

+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.
2. If fitted:Remove 4 nuts securing engine oil
cooler to mounting bracket and position oil
cooler aside.
3.Remove bolt securing dipstick tube to cylinder
block.
4.Depress and hold down dipstick tube collar;
remove dipstick tube from sump.5.Using sequence shown and noting their fitted
positions, remove 10 bolts securing sump to
lower crankcase.
6.Using a mallet, gently tap sump sideways to
break sealant bond, remove sump.
CAUTION: Do not lever between crankcase
and sump.
M12 7916
M12 6672

ENGINE - K SERIES KV6
OVERHAUL 12-3-107
Refit
1.Using a suitable cleaning solvent, clean sump
and mating face on lower crankcase. DO NOT
use a metal scraper on sealing surfaces.
2.Apply a 2 mm (0.1 in) bead of sealant, Part No.
STC 4600 along centre of sump flange, then
spread to an even film using a roller.
CAUTION: To avoid contamination,
assembly should be completed immediately
after application of sealant.
3.Position sump, fit bolts and tighten
progressively in the sequence shown to 35 Nm
(26 lbf.ft).
4. If fitted:Position engine oil cooler to sump
mounting bracket, fit and tighten nuts to 25 Nm
(18 lbf.ft).
5.Position dipstick tube to sump and cylinder
block, fit bolt and tighten to 9 Nm (7 lbf.ft).
6.Fill engine with oil.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
Camshaft timing belt
$% 12.65.18.01
Remove
1.Remove 4 bolts securing engine mounting
bracket to engine front plate and remove
bracket.
2.Release and remove ancillary drive belt from
remaining pulleys.
3.Remove 2 bolts securing ancillary drive belt
tensioner and remove tensioner.
M12 6675
10
9
135
8
4
7
26
M86 5264

ENGINE - K SERIES KV6
12-3-108 OVERHAUL
4.Remove Torx screw securing idler pulley to
front mounting plate and remove pulley.
5.Release alternator battery lead terminal cover,
loosen terminal nut and disconnect lead from
terminal
6.Disconnect multiplug from alternator.
7.Remove lower bolt and upper nut and bolt
securing alternator to front mounting plate.
8.Release alternator and remove.9.Remove 3 bolts securing camshaft timing belt
LH rear cover and remove cover.
10.Remove inlet manifold chamber - if fitted.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.
11.Remove 2 bolts securing RH rear timing belt
cover heat shield to cylinder head; remove heat
shield.
12.Remove 3 bolts securing RH rear timing belt
cover; remove cover.
M12 6694

ENGINE - K SERIES KV6
OVERHAUL 12-3-109
13.Using a socket on crankshaft pulley bolt, rotate
crankshaft in a clockwise direction and align the
engine "SAFE" position - notch on crankshaft
pulley aligned to the "ARROW" on front
mounting plate. Check that the timing marks on
the rear camshaft gears are aligned as
illustrated.
CAUTION: Do not use the camshaft gear
bolts or timing belts to rotate the
crankshaft. Do not use the arrow on the oil
pump body as a timing reference.
14.Insert timing pin LRT-12-232 through hole
immediately adjacent to side of lower
crankcase ensuring that pin is located in hole in
drive plate.15.Remove 3 bolts securing camshaft timing belt
LH front cover and remove cover.
16.Remove 3 bolts securing camshaft timing belt
RH front cover and remove cover.
17.Remove bolt securing dipstick tube to cylinder
block.
18.Depress locking collar, release and remove
dipstick tube from engine sump.
LRT-12-232
M12 7927
M12 6672

ENGINE - K SERIES KV6
12-3-110 OVERHAUL
19.Assemble LRT-12-161 to LRT-12-199 and
secure with clamp bolt.
20.Insert LRT-12-161 with LRT-12-199 into
crankshaft pulley, loosen and remove pulley
bolt.
CAUTION: Ensure crankshaft does not
rotate during above operation.
21.Remove LRT-12-161 and LRT-12-199 from
crankshaft pulley.
22.Remove crankshaft pulley.
23.Remove 3 bolts securing camshaft timing belt
lower cover to cylinder block and remove cover.24.Remove 3 bolts securing engine front mounting
plate and lifting bracket to cylinder block.
25.Remove bolt securing lifting bracket to RH
cylinder head and remove lifting bracket.
26.Remove rubber blanking plug from around
camshaft timing belt tensioner.

ENGINE - K SERIES KV6
OVERHAUL 12-3-111
27.Remove 5 bolts and 2 pillar bolts securing
engine front mounting plate to cylinder block.
28.Remove 2 bolts securing IRD support bracket
to engine front mounting plate.
29.With care, release and remove front mounting
plate from engine.
30.Fit a suitable 1.5 mm diameter pin through hole
in tensioner body and into hole in plunger.
NOTE: If holes in body and plunger are not
aligned, move tensioner backplate using a
broad bladed screwdriver; this will move the
plunger sufficiently to align the holes and allow
the pin to be inserted.31.Remove and discard 2 Patchlok bolts securing
tensioner to cylinder block and remove
tensioner.
CAUTION: Exercise great care when
removing bolts, do not apply excessive
torque. If bolts appear to be seized, apply
suitable anti-seize lubricant prior to
removing bolts. DO NOT loosen Allen screw
securing tensioner pulley.
32.If camshaft timing belt is to be refitted, mark
direction of rotation on timing belt before
removal.
33.With care, ease camshaft timing belt from
gears using fingers only and remove timing
belt.
CAUTION: Do not rotate crankshaft or
camshafts with timing belt removed.
CAUTION: Camshaft timing belt must be
replaced if cylinder head is to be removed or
new drive gears, tensioner or coolant pump
are to be fitted. Camshaft timing belts must
be stored and handled with care. Always
store a camshaft timing belt on its edge with
a bend radius greater than 50 mm (2.0 in).
Do not use a camshaft timing belt that has
been twisted or bent double as this will
damage the reinforcing fibres. Do not use a
camshaft timing belt if debris other than belt
dust is found in timing belt covers. Do not
use a camshaft timing belt if partial engine
seizure has occurred. Do not use a
camshaft timing belt if mileage exceeds
72,000 km (45,000 miles). Do not use an oil
or coolant contaminated timing belt, cause
of contamination must be rectified.
34.Remove and discard LH and RH exhaust
camshaft cap seals.

ENGINE - K SERIES KV6
12-3-112 OVERHAUL
35.Position tools LRT-12-196 to LH and RH 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.
36.Remove and discard bolts retaining front inlet
camshaft gears to camshafts.
37.Remove tools LRT-12-196 from both inlet
camshaft gears and exhaust camshafts.
38.Remove camshaft drive gears and hub
assemblies.
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 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.
2.Fit hubs to camshaft gears and fit gears to
camshafts.
3.Fit new camshaft gear bolts; tighten bolts
sufficiently to allow gears to rotate without
tipping.4.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.
5.Fit tool LRT-12-197 into each exhaust
camshaft in turn.
6.Using assistance, rotate each exhaust
camshaft slightly and align timing marks on LH
and RH rear camshaft gears.
7.Remove tool LRT-12-197.
8.Fit tools LRT-12-175 to LH and RH rear
camshaft gears.
9.Rotate both front camshaft gears fully
clockwise as viewed from front of engine.
10.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.

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.