light LAND ROVER FREELANDER 2001 Owner's Guide

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
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
12-3-112 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.

INTERMEDIATE REDUCTION DRIVE
41-22 REPAIRS
Refit
1.Clean pinion shaft, drive flange and housing.
2.Clean oil seal recess.
3.Lubricate and fit bearing to pinion housing.
4.Lubricate new seal.
5.Using a suitable adapter, press seal into
housing.
CAUTION: Oil seal must be flush with end of
pinion housing.
6.Assemble pinion to housing using new
collapsible spacer.
7.Lightly lubricate drive flange splines with
Molybdenum Disulphide grease.
8.Align pinion to drive flange reference marks
and press flange onto pinion shaft until a 2 mm
clearance exists in bearings.
9.Fit pinion assembly to mounting plate and
secure in vice.
10.Fit new pinion nut, hold pinion drive flange
using LRT-51-003 and tighten pinion nut to 150
Nm (111 lbf.ft).
11.Check pinion torque to turn figure.
NOTE: Figure for new bearings is 180 to 200
Ncm.
If original bearing figure is above 20 to 30 Ncm
and below new bearing figure, set to figure
recorded.
If original bearing is below 20 Ncm set to 20 to
30 Ncm.12.If turning torque is too low, carefully tighten nut
and recheck reading. If turning torque is too
high, pinion assembly will have to be
dismantled and a new collapsible spacer fitted.
Reassemble using new nut and recheck turning
torque.
13.Check drive flange run-out using a Dial Test
Indicator (DTI).
CAUTION: The drive flange run-out should
not exceed 0.05 mm.
14.Remove pinion housing from vice and
mounting plate.
15.Fit pinion housing.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - Td4.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - K1.8.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - KV6 - Non NAS.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - KV6 - NAS.

STEERING
57-4 ADJUSTMENTS
Power steering - pressure test
$% 57.90.10.01
Check
1.Position absorbent cloth to catch spillage.
2.Remove bolt securing PAS high pressure pipe
clip to PAS pump.
3.Loosen union securing high pressure pipe to
PAS pump and release pipe.
4. K1.8 models: Fit adaptor LRT-57-034A to high
pressure port of PAS pump.
5. KV6 & Td4 models: Fit adaptor LRT-57-042 to
high pressure port of PAS pump.
6.Fit adaptor LRT-57-035 to existing high
pressure hose.
7.Fit hose LRT-57-002 to each adaptor.
8.Fit pressure gauge LRT-57-005 to test valve
LRT-57-001
9.Connect hoses LRT-57-002 to LRT-57-001
and tighten unions.
10.Ensure steering system and test equipment is
free from leaks.
11.Maintain maximum fluid level during test.
12.With the test valve open, start the engine.
13.Pressure at idle should be between 5 and 7
bar.
14.With the engine at idle, slowly turn the steering
wheel and hold on full lock.
15.Repeat procedure for other side.
16.Test pressure should rise significantly as
steering wheel is rotated and continue to rise as
full lock is approached. For full lock pressures,
refer to general data section.

+ GENERAL DATA, Steering.
17.With the engine at idle, release steering wheel.
For idle pressure, refer to general data section.

+ GENERAL DATA, Steering.
18.Pressures outside the above tolerance
indicates a fault.19.To determine if fault is in steering pump or
steering rack, close the test valve for a
maximum of 5 seconds.
CAUTION: Pump damage will occur if test
valve is closed for longer periods.
20.If gauge does not register correct reading,
suspect faulty pump.
21.If PAS pump pressure is correct and steering is
heavy at idle and becomes light as engine RPM
is increased, suspect pump flow rate.
22.If maximum pump pressure is correct, suspect
steering rack.
23.On completion stop engine and remove test
equipment.
24.Clean PAS pump and pipe union.
25.Fit new 'O' ring to high pressure pipe, align to
PAS pump and tighten union to 25 Nm (18
lbf.ft).
26.Fit bolt securing high pressure pipe clip and
tighten to 8 Nm (6 lbf.ft).
27.Check and top-up PAS fluid level.

+ MAINTENANCE, MAINTENANCE,
Intermediate Reduction Drive - Non NAS
models.

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
57-22 REPAIRS
Refit
1.Remove column from vice.
2.Fit new cable ties to steering column.
3. Models with automatic transmission: Fit key
interlock cable clip.
4.Position steering column to vehicle, locate
steering column on PAS rack, aligning column
coupling with PAS rack input flag.
5.Locate steering column on studs fit nuts but do
not tighten at this stage.
6.Fit bolts and snubber to pivot mountings and
tighten bolts to 14 Nm (10 lbf.ft).
7.Tighten nuts to 14 Nm (10 lbf.ft).
8.Fit and tighten PAS rack pinion clamp bolt to 32
Nm (24 lbf.ft).
CAUTION: Nuts and bolts must be tightened
with weight of vehicle on suspension.
9. Models with automatic transmission:
Remove clamp bolt from height adjuster and
position key interlock cable.
10. Models with automatic transmission: 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.
11. Models with automatic transmission: 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.
12. Models with automatic transmission:
Remove starter key from column lock.
13. Models with automatic transmission: Align
key interlock cable to column lock and tighten
union to 4 Nm (3 lbf.ft).
14. Models with automatic
transmission:Position lock to steering column
assembly and fit shear bolts. Do not tighten
shear bolts at this stage.
15. Models with automatic transmission: Insert
starter key, check operation of steering lock
and that key turns freely.
16. Models with automatic transmission:
Ensure correct operation of key interlock cable.
17. Models with automatic transmission:
Remove starter key from column lock.
18. Models with automatic transmission:
Tighten shear bolts fully and shear heads off.
19. Models with automatic transmission: Fit
passive coil.
20. Models with automatic transmission:
Position ignition switch to column, fit and
tighten screws.
21. Models with automatic transmission:
Secure key interlock cable in clip.
22. Models with automatic transmission:
Ensure key interlock cable is correctly fitted.23.Fit side support bolt and tighten to 10 Nm (7.5
lbf.ft).
24.Position harness and secure cable ties.
25.Fit fusebox cover and close glove box lid.
26.Connect multiplugs to column switch and
passive coil.
27.Fit aperture trim and secure with screws.
28. Fit steering column multi purpose switch.

+ LIGHTING, REPAIRS, Switch -
combined direction indicator/headlight/
horn.
29.Connect battery earth lead.

BRAKES
70-2 ADJUSTMENTS
Cable - handbrake - check and adjust
$% 70.35.10
Check
1.Release ash tray panel from rear console,
disconnect multiplug from power socket and
remove ash tray panel.
2.Fully release handbrake lever.
3.With engine running, apply footbrake a
minimum of thirty times, to ensure full
adjustment of rear brake shoes.
4.Switch off engine.
5.Apply handbrake lever one notch at a time and
count the number of notches required to apply
the brakes firmly, equivalent to a pull of 20 kgf.
applied at mid point of handbrake lever grip.
Handbrake lever travel = 4 to 7 notches.
6.Adjust handbrake cable tension if travel is
outside limits.
CAUTION: Hand brake travel must be within
the limits given or the automatic adjusters
may not work.Adjust
1.If carrying out handbrake adjustment after
brake drum installation, apply brake pedal a
min. of 30 times, to ensure full adjustment of
rear brake shoes.
2.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
3.Check handbrake cable connections for free
movement in handbrake equalizer.
4.Apply handbrake lever one notch.
5.Tighten equalizer adjusting nut until rear
wheels drag slightly when turned.
6.Release handbrake lever and check that rear
wheels do not drag when turned. Adjust if
necessary.
7.Apply handbrake one notch at a time and count
the number of notches until both rear wheels
lock. This should be a minimum of 4 and a
maximum of 7 clicks. Adjust if necessary.
8.Release handbrake
9.Fit ash tray panel and cigar lighter to rear
console.
10.Remove stands and lower vehicle.

BRAKES
REPAIRS 70-11
Cable - handbrake
$% 70.35.25
Remove
1.Raise rear 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 road wheel(s).
3.Release rear ash tray, disconnect connector
from cigar lighter and remove ash tray.
4.Remove cable adjusting nut.
5.Remove 2 bolts securing cable retaining plate
to body and remove plate.
6.Release equalizer from adjusting rod.
7.Release cable from equalizer plate.
8.Remove 2 bolts securing cable to body and
subframe.
9.Release cable from chassis clip.10.Release cable grommet from floor and pull
cable from interior.
11.Remove rear brake shoes.

+ BRAKES, REPAIRS, Brake Shoes -
rear set.
12.Using tool LRT-70-007 release cable retainer
from backplate and withdraw cable from
vehicle.

BRAKES
70-12 REPAIRS
Refit
1.Manoeuvre cable into position and secure floor
grommet.
2.Fit and secure handbrake cable to backplate.
3.Fit brake shoes.

+ BRAKES, REPAIRS, Brake Shoes -
rear set.
4.Align cable clips, fit bolts and tighten to 22 Nm
(16 lbf.ft).
5.Secure cable in chassis clip.
6.Connect handbrake cable to equalizer.
7.Ensure spring is in place and fit equalizer to
adjusting rod.
8.Fit cable adjusting nut.
9.Fit cable retaining plate, fit bolts and tighten to
22 Nm (16 lbf.ft).
10.Adjust handbrake cable.

+ BRAKES, ADJUSTMENTS, Cable -
handbrake - check and adjust.
11.Fit ash tray and cigar lighter to rear console.
12.Fit road wheel(s).
13.Remove stands and lower vehicle.
Switch - handbrake warning
$% 70.35.40
Remove
1.Remove rear console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - rear.
2.Disconnect Lucar from handbrake warning
switch.
3.Release switch from handbrake.
Refit
1.Fit switch to handbrake and connect Lucar.
2.Fit rear console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - rear.