check engine LAND ROVER FREELANDER 2001 Service Manual

ENGINE - K SERIES KV6
OVERHAUL 12-3-89
13.Using sequence shown, progressively loosen
and remove 8 cylinder head bolts.
14.Remove cylinder head.
CAUTION: Support both ends of cylinder
head on blocks of wood.
15.Remove and discard cylinder head gasket.
CAUTION: Do not rotate crankshaft with RH
cylinder head fitted.
16.Fit cylinder liner clamps LRT-12-144 and
secure with cylinder head bolts.
CAUTION: Ensure that feet of clamps do not
protrude over bores.Refit
1.Clean cylinder head face.
CAUTION: Use suitable gasket removal
spray and a plastic scraper.
2.Remove bolts securing cylinder liner clamps
LRT-12-144 to cylinder block and remove
clamps.
CAUTION: Do not rotate crankshaft.
3.Clean cylinder block face and dowel holes.
4.Clean cylinder head bolts and wipe dry.
5.Lightly lubricate threads and beneath heads of
cylinder head bolts with clean engine oil.
6.Check that fitted height of dowels is between 10
to 11 mm (0.40 to 0.43 in) above cylinder block
top face. Replace dowels if fitted height is
incorrect.
7.Fit new cylinder head gasket onto cylinder
block with the word 'TOP' uppermost.
8.With assistance, fit cylinder head and carefully
position LH inlet to RH inlet manifold.
9.Carefully enter cylinder head bolts, DO NOT
DROP. Screw bolts into place by hand.

ENGINE - K SERIES KV6
OVERHAUL 12-3-93
18.Fit cylinder liner clamps LRT-12-144 and
secure with cylinder head bolts.
CAUTION: Ensure that feet of clamps do not
protrude over bores.
Refit
1.Clean cylinder head face.
CAUTION: Use suitable gasket removal
spray and a plastic scraper.
2.Remove bolts securing cylinder liner clamps
LRT-12-144 to cylinder block and remove
clamps.
CAUTION: Do not rotate crankshaft.
3.Clean cylinder block face, dowels and dowel
holes.
4.Clean cylinder head bolts and wipe dry.
5.Lightly lubricate threads and beneath heads of
cylinder head bolts with clean engine oil.6.Check that fitted height of dowels is between 10
to 11 mm (0.40 to 0.43 in) above cylinder block
top face. Replace dowels if fitted height is
incorrect.
7.Fit new cylinder head gasket onto cylinder
block with the word 'TOP' uppermost.
8.With assistance, fit cylinder head and carefully
position RH inlet to LH inlet manifold.
9.Carefully enter cylinder head bolts, DO NOT
DROP. Screw bolts into place by hand.
10.Using sequence shown, tighten cylinder head
bolts progressively to:
lStage 1 - 25 Nm (18 lbf.ft)
lStage 2 - 25 Nm (18 lbf.ft)
lStage 3 - 25 Nm (18 lbf.ft)
lStage 4 - Further 180°
11.Fit RH camshaft cover gasket.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - RH.
12.Remove and discard lower 'O' rings from
injectors.
13.Clean injectors and injector locations in fuel rail.
14.Lubricate new 'O' rings with castor oil and fit to
injectors.
15.Position fuel rail assembly and secure injectors
to inlet manifolds.

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
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
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
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
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