LAND ROVER FREELANDER 2001 Workshop Manual

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-28 OVERHAUL
12. NAS models: Remove clip securing vacuum/
breather pipe to engine air intake hose and
disconnect vacuum/breather pipe from air
intake hose. Discard clip.
CAUTION: Always fit plugs to open
connections to prevent contamination.
13. NAS models: Depress locking collars and
release vacuum/breather pipe from LH
camshaft cover, RH camshaft cover link pipe
and inlet manifold chamber. Remove pipe.
CAUTION: Always fit plugs to open
connections to prevent contamination.
14. NAS models: Disconnect multiplug from IAT
and MAF sensors.
15. NAS models: Disconnect multiplug from
throttle body.
16. NAS models: Remove clip securing intake
hose to throttle body, remove intake hose and
MAF sensor assembly. Discard clip.
17. NAS models: Release harness and fuel feed
pipe from clip on inlet manifold chamber.
18.Disconnect multiplugs from VIS motors.19.Remove 2 screws securing engine harness
brackets to inlet manifold chamber and position
harness aside.
20.Release 3 locking clips and disconnect 3
multiplugs from RH plug top coils.
21.Release 2 clips securing RH plug top coil
harness to inlet manifold chamber support
brackets.
M30 1173
M30 1176

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
OVERHAUL 30-3-29
22.Remove 2 bolts securing inlet manifold
chamber rear support brackets to RH camshaft
cover.
23.Remove 4 bolts securing inlet manifold
chamber to LH inlet manifold.24.Remove and discard seals from inlet manifold
chamber and 'O' rings from RH inlet manifold.
M30 1175

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-30 OVERHAUL
Refit
1.Clean seal faces on inlet manifold chamber and
inlet manifolds.
2.Fit new 'O' rings to RH inlet manifold and new
seals to inlet manifold chamber.
3.Fit inlet manifold chamber to inlet manifolds
and tighten bolts to 18 Nm (13 lbf.ft).
4.Align inlet manifold chamber support brackets
to RH camshaft cover, fit and tighten bolts to 10
Nm (7 lbf.ft).
5.Position engine harness brackets to inlet
manifold chamber, fit and tighten screws.
6.Secure RH plug top coil harness to manifold
chamber support brackets.
7.Connect multiplugs to plug top coils and secure
with locking clips.
8.Connect multiplugs to VIS motors.
9. NAS models: Align harness and fuel feed pipe.
Secure harness and pipe in clip on manifold
chamber.
10. NAS models: Using a new clip, fit intake hose
to throttle body and secure hose with clip.
11. NAS models: Connect multiplug to throttle
body.
12. NAS models: Connect multiplugs to IAT and
MAF sensors.13. NAS models: Fit vacuum/breather pipe and
connect to LH camshaft cover, RH camshaft
cover link pipe and inlet manifold chamber.
14. NAS models: Using a new clip, fit vacuum/
breather pipe to engine air intake hose and
secure pipe with clip.
15. NAS models: Connect vacuum/breather pipe
to LH and RH camshaft covers. Fit pipe into
clip.
16. Non NAS models: Fit vacuum/breather pipe to
throttle body and connect pipe to LH and RH
camshaft covers.
17. Non NAS models: Fit vacuum/breather pipe to
purge control valve and LH camshaft cover.
Using a new clip, connect pipe to 'T' piece and
secure pipe with clip.
18. Non NAS models: Connect multiplug to TP
sensor.
19. Non NAS models: Connect multiplug to IACV.
20. Non NAS models: Connect vacuum pipe to
IACV.
21. Non NAS models: Connect small vacuum pipe
to purge control valve..
22.Connect multiplug to purge control valve .
23.Fit vacuum enhancer and connect to inlet
manifold chamber.
24.Using a new clip, connect vacuum enhancer to
intake hose and secure hose with clip.

INTERMEDIATE REDUCTION DRIVE
ADJUSTMENTS 41-1
INTERMEDIATE RE DUCTION DRIVE ADJUST ME NTS
Intermediate reduction drive (IRD) fluid -
drain & refill - Non NAS
$% 41.25.06
Drain
1.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
2.Place container beneath IRD unit.
WARNING: Observe due care when draining
gearbox fluid as the fluid can be very hot.
3.Clean area around filler/level and drain plugs.
4.Remove filler/drain plugs and discard sealing
washers. Allow fluid to drain.
NOTE: The fluid should be drained with the
transmission at normal operating temperature.
5.Fit new sealing washer and tighten drain plug to
35 Nm (26 lbf.ft).Refill
1.Fill with correct fluid until it just runs from filler/
level hole. Allow sufficient time for fluid to flow
and reach a common level in unit.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
2.Fit new sealing washer and tighten filler/level
plug to 35 Nm (26 lbf.ft).
3.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.

INTERMEDIATE REDUCTION DRIVE
41-2 ADJUSTMENTS
Intermediate reduction drive (IRD)
lubrication system - drain & refill - NAS
$% 41.25.06
Drain
1.Remove underbelly panel

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
2.Place container beneath IRD unit.
WARNING: Observe due care when draining
gearbox fluid as the fluid can be very hot.
3.Clean area around filler/level and drain plugs.
4.Using LRT-41-021 remove filler plug and
discard sealing washer.5.Remove drain plug, discard sealing washer and
allow oil to drain.
NOTE: The fluid should be drained with the
transmission at normal operating temperature.
6.Fit new sealing washer and tighten drain plug to
35 Nm (26 lbf.ft).
Refill
1.Fill with fluid until it just runs from filler/level
hole. Allow sufficient time for fluid to flow and
reach a common level in unit.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
2.Fit new sealing washer and tighten filler/level
plug to 35 Nm (26 lbf.ft).
3.Fit underbelly panel

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
M417853
LRT-41-021
M41 7687

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-3
REPAIRS
Intermediate reduction drive (IRD) unit -
Td4
$% 41.25.01.99
Remove
1.Disconnect battery earth lead.
2.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.
3.Remove rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
4.Remove exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - front.
5.Drain fluid from IRD.

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

+ MANUAL GEARBOX - GETRAG,
ADJUSTMENTS, Gearbox oil - drain and
refill.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
7.Remove 3 bolts securing RH splash shield to
body and remove shield.8.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release drive shaft from
IRD.
9.With assistance, pull hub outwards and release
drive shaft from IRD.
10.Remove and discard drive shaft circlip.
11.Reference mark front propeller shaft for
reassembly.
12.Raise one rear wheel for rotation of propeller
shaft to access bolts.

INTERMEDIATE REDUCTION DRIVE
41-4 REPAIRS
13.Remove 6 nuts and bolts securing propeller
shaft to IRD drive flange.
14.Release propeller shaft from IRD drive flange
and tie shaft aside.
CAUTION: Care must be taken to support
the Tripode joint when removed from the
IRD unit. To avoid damage to gaiter or steel
can, the joint should not be allowed to fully
extend or be dropped.
15.Disconnect breather hose from IRD housing.
16.Position container to collect coolant spillage.17.Release clips and disconnect coolant hoses
from IRD.
18.Remove bolt securing engine lower steady to
IRD support bracket.
19.Remove lower engine steady noting that 'TOP'
mark on engine steady faces uppermost.
20.Remove 3 bolts securing IRD support bracket
to sump.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-5
21.Remove 2 bolts securing support bracket to
IRD.
22.Remove support bracket.
23.Remove 3 bolts, securing IRD upper support
bracket to cylinder block.
24.Remove 2 bolts securing upper support bracket
to IRD.
25.Remove IRD upper support bracket.
26.Remove 4 bolts securing IRD.
27.With assistance, release IRD from gearbox and
remove.28.Remove and discard 'O' ring from IRD.
M41 7698

INTERMEDIATE REDUCTION DRIVE
41-6 REPAIRS
Refit
1.Clean mating faces of IRD and gearbox.
2.Lubricate and fit new 'O' ring
3.With assistance, fit IRD.
4.Fit bolts securing IRD to gearbox and tighten
sufficiently only to pull mating faces of IRD and
gearbox together at this stage.
5.Fit IRD support brackets, tighten sufficiently to
pull mating faces together.
6.Final tighten bolts securing IRD to gearbox to
90 Nm (66 lbf.ft).
7.Final tighten bolts securing IRD support
brackets in the following sequence:
lM8 bolts securing support brackets to IRD
37 Nm (22 lbf.ft)
lM10 bolts securing support brackets to IRD
50 Nm (22 lbf.ft)
l3 bolts securing support bracket to cylinder
block 25 Nm (18 lbf.ft)
l3 bolts securing support bracket to sump at
45 Nm (33 lbf.ft).
8.Position lower engine steady, 'TOP' mark
uppermost. Fit bolt but do not tighten at this
stage.
9.Connect coolant hoses and secure with clips.
10.Connect breather hose to IRD housing.
11.Clean propeller shaft flange and mating face.
12.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 40 Nm (30
lbf.ft).
13.Inspect drive shaft oil seal, renew if worn or
damaged.14.Clean drive shaft and flange splines.
15.Fit new circlip to drive shaft.
16.With assistance, pull hub outwards, align drive
shaft and fit to IRD taking care not to damage
oil seal.
17.Fit splash shield and secure with bolts.
18.Fit exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - front.
19.Fit rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
20.Final tighten bolt securing lower engine steady
to IRD support bracket to 100 Nm (74 lbf.ft).
21.Remove stand(s) and lower vehicle.
22.Fill IRD to correct level with fluid.

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

+ MANUAL GEARBOX - GETRAG,
ADJUSTMENTS, Gearbox oil - drain and
refill.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
24.Connect battery earth lead.
25.Refill cooling system.

+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-7
Intermediate reduction drive (IRD) unit -
K1.8
$% 41.25.01.99
Remove
1.Disconnect battery earth lead.
2.Remove rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
3.Remove exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES 1.8, REPAIRS, Exhaust pipe -
front.
4.Drain fluid from IRD.

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

+ MANUAL GEARBOX - PG1,
ADJUSTMENTS, Gearbox oil - drain and
refill.
6.Remove 3 bolts securing RH splash shield to
body and remove shield.7.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release drive shaft from
IRD.
8.With assistance, pull hub outwards and release
drive shaft from IRD.
CAUTION: Care must be taken not to
damage oil seal when removing drive shaft
from IRD.
9.Remove and discard drive shaft circlip.