sensor LAND ROVER FREELANDER 2001 Service Manual

ENGINE - K SERIES KV6
REPAIRS 12-3-43
78.Remove 3 Torx screws securing PAS pump
pulley and remove pulley.
79.Remove 3 bolts securing PAS pump to front
mounting plate and tie pump aside.
80.With assistance, manoeuvre and lower engine
and gearbox to floor.
Refit
1.With assistance, raise engine and gearbox into
engine compartment.
2.Position PAS pump to front mounting plate, fit
and tighten bolts to 25 Nm.
3.Position PAS pump pulley, fit and tighten Torx
screws to 9 Nm.
4.Position top arm to engine mounting bracket
and RH hydramount, fit and tighten bolts to 100
Nm.
5.Position PAS pipe support bracket to RH
hydramount, fit and tighten nut to 85 Nm.
6.Place a wooden block on jack, position jack
under gearbox and raise jack sufficient to
support weight of gearbox. Release lifting hook
from lifting bracket on gearbox and connect to
rear engine lifting bracket.
7.Lower and remove jack supporting gearbox.8.Remove bolts securing 44-026 lifting bracket to
gearbox and remove bracket.
9.Position LH mounting bracket to gearbox, fit
and tighten bolts to 85 Nm.
10.Position LH mounting to body, fit and tighten
bolts to 48 Nm.
11.Align gearbox bracket to LH body mounting, fit
and tighten through bolt to 100 Nm.
12.Position upper RH engine steady to top arm, fit
and tighten bolt to 100 Nm.
13.Tighten bolt securing upper RH engine steady
to body to 100 Nm.
14.Position PAS pipe to engine front mounting
plate, fit and tighten bolt to 25 Nm.
15.Lower hoist, disconnect and remove lifting
bracket, LRT-12-138.
16.Raise vehicle on lift.
17.Position A/C compressor to front mounting
plate and cylinder block, align heat shield, fit
and tighten bolts to 25 Nm.
18.Connect multiplug to A/C compressor.
19.Using a 3/8" square drive socket bar, raise
ancillary drive belt tensioner and fit drive belt to
pulleys.
20.Position selector cable to gearbox bracket and
secure with clip.
21.Position selector lever to selector shaft, fit and
tighten nut to 25 Nm.
22.Clean splines and seal areas on each drive
shaft and mating faces in front hubs.
23.Fit new circlips to RH and LH drive shaft inner
joint splines.
24.Fit drive shafts to IRD and gearbox, ensuring
that the circlip on each drive shaft is fully
engaged.
25.Engage LH and RH drive shafts into front hubs.
26.Fit new drive shaft flange nuts but do not tighten
at this stage.
27.Clean ball joint tapers and taper seats.
28.Position LH and RH track rod ends to steering
arms, fit new nuts and tighten to 55 Nm.
29.Clean ABS sensors and mating faces.
30.Apply anti-seize grease to both ABS sensors
and position sensors in front hubs.
CAUTION: Ensure ABS sensor is fully
located into hub, so that sensor touches
pole wheel teeth.
31.Position LH and RH brake hoses to front
damper brackets and secure with clips.
32.Position LH and RH splash shields, fit and
tighten bolts.
33.Ensure mating face of propeller shaft and IRD
drive flange are clean.
34.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 42 Nm (31
lbf.ft).

ENGINE - K SERIES KV6
12-3-44 REPAIRS
35.Fit rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
36.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
37.Fit exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - NAS.
38.With assistant depressing the brake pedal,
tighten front hub nuts to 400 Nm.
39.Stake nuts to drive shafts
40.Fit front road wheels, fit and tighten nuts to 115
Nm.
41.Lower vehicle on lift.
42.Connect brake servo vacuum hose to inlet
manifold chamber.
43.Connect coolant hose to underside of
expansion tank and secure with clip.
44.Connect expansion tank hose to inlet manifold
and secure clip.
45.Connect top hose to radiator and secure with
clip. Position hose in bracket.
46.Connect heater feed and return hoses and
secure with clips.
47.Connect throttle inner cable to throttle cam and
secure outer cable in abutment bracket.
48.Connect hose to purge valve.
49.Fit purge hose into clip.
50.Connect fuel hose to fuel rail pipe, fit rubber
sleeve over hose connector.
51.Connect gearbox harness multiplugs and
secure multiplugs in mounting bracket clips.
52.Connect Lucar connector to starter solenoid.
53.Position earth lead to gearbox housing, fit and
tighten bolt to 25 Nm.
54.Position engine harness to 'E' box mounting
bracket and secure with clips.
55.Connect earth header multiplug.
56.Connect multiplug to under bonnet fuse box.
57.Position battery and starter motor lead to under
bonnet fuse box, fit and tighten bolts to 8 Nm.
58.Fit under bonnet fuse box cover.
59.Position 'E' box, secure in retaining clip, fit and
tighten nut to 9 Nm.
60.Fit carrier to 'E' box.
61.Fit air ducting to 'E' box.
62.Fit body harness to 'E' box, secure grommet
and harness clip.
63.Connect 'E' box cooling fan multiplug.
64.Connect multiplug to 'E' box temperature
sensor.
65.Connect multiplug to gearbox ECU.
66.Position engine harness to 'E' box and secure
grommet.67.Fit engine harness clamp and secure with
screws.
68.Connect engine harness multiplug to body
harness multiplug and fit multiplug to 'E' box.
69.Fit heated front screen harness to battery
positive cable and tighten bolt to 15 Nm (11
lbf.ft).
70.Fit engine ECM.

+ ENGINE MANAGEMENT SYSTEM -
SIEMENS, REPAIRS, Engine control module
(ECM) - fuel - NAS.
71.Fit battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
72.Fill cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
73.Connect the battery earth lead.
74.Fill gearbox with fluid.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
75.Fit the engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
76.Untie and close bonnet.

ENGINE MANAGEMENT SYSTEM - SIEMENS
18-3-8 REPAIRS
Sensor - intake air temperature (IAT) -
NAS
$% 18.30.09
Remove
1.Disconnect multiplug from IAT sensor.
2.Release clip and remove IAT sensor. Discard
seal.
Refit
1.Clean IAT sensor and mating face.
2.Fit new seal to sensor.
3.Fit IAT sensor and connect multiplug.
Sensor - engine coolant temperature
(ECT)
$% 18.30.10
Remove
1.Disconnect battery earth lead.
2.Remove thermostat.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Thermostat.
3.Disconnect multiplug from coolant temperature
sensor.
4.Remove coolant temperature sensor and
discard sealing washer.
5.Remove coolant temperature sensor from
cylinder block.
6.Remove steel shim and sealing washer from
temperature sensor, discard sealing washer.
Refit
1.Clean coolant temperature sensor and mating
face on cylinder block.
2.Fit new sealing washer, then steel shim to
coolant temperature sensor.
3.Position coolant temperature sensor and
tighten to 17 Nm (12.5 lbf.ft).
4.Fit thermostat.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Thermostat.
5.Connect battery earth lead.

ENGINE MANAGEMENT SYSTEM - SIEMENS
REPAIRS 18-3-9
Sensor - crankshaft position (CKP)
$% 18.30.12
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Disconnect CKP sensor multiplug from engine
harness.
4.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Remove bolt securing CKP sensor to gearbox
housing and remove sensor.Refit
1.Clean CKP sensor and mating face.
2.Position CKP sensor, fit and tighten bolt to 9
Nm (6.5 lbf.ft).
3.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
4.Connect CKP sensor multiplug to engine
harness.
5.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
6.Connect battery earth lead.

ENGINE MANAGEMENT SYSTEM - SIEMENS
18-3-10 REPAIRS
Sensor - throttle position (TP)
$% 18.30.17
Remove
1.Disconnect battery earth lead.
2.Remove acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Disconnect multiplug from TP sensor.
4.Remove and discard 2 Torx screws and wave
washers securing TP sensor to inlet manifold.
5.Remove TP sensor specification plate.6.Pull TP sensor from throttle spindle.
CAUTION: Do not twist or apply leverage to
throttle position sensor.
Refit
1.Clean mating faces of throttle housing and TP
sensor.
2.Fit TP sensor to throttle spindle. Ensure that
during fitting the machined flat on the throttle
spindle is aligned with the mating portion of the
TP sensor
CAUTION: The throttle position sensor can
be easily damaged during fitting. When
pressing the sensor onto the throttle
spindle, use fingers only, and only apply
pressure to the area shown shaded in the
illustration.
3.Rotate TP sensor in an anti-clockwise direction
to align fixing holes.
CAUTION: Do not rotate throttle position
sensor in a clockwise direction and ensure
that it is not rotated beyond its internal
stops.
4.Fit TP sensor specification plate.
M18 0695

ENGINE MANAGEMENT SYSTEM - SIEMENS
REPAIRS 18-3-11
5.Fit new Torx screws and wave washers, tighten
Torx screws to 1.5 Nm (1.1 lbf.ft).
6.Connect multiplug to TP sensor.
7.Operate throttle cable cam 2 or 3 times and
ensure that full travel to the throttle open and
the throttle closed positions is available.
8.Fit acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
9.Connect battery earth lead.
NOTE: A ‘throttle initialisation’ procedure
MUST be carried out using TestBook/T4
whenever the TP sensor is removed or
renewed.
Sensor - thermostat monitoring (TM) -
KV6 - NAS
$% 18.30.21
Remove
1.Disconnect battery earth lead.
2.Remove coolant expansion tank cap to release
pressure and refit cap.
WARNING: Since injury such as scalding
could be caused by escaping steam or
coolant, do not remove the filler cap from
the coolant expansion tank while the
system is hot.
3.Position absorbent cloth under TM sensor to
collect spillage.
4.Disconnect multiplug from TM sensor.
5.Release and remove sensor. Discard seal.
Refit
1.Clean sensor and mating face.
2.Using a new seal, fit and secure sensor.
3.Connect multiplug to sensor.
4.Remove absorbent cloth.
5.Check for leaks and fill expansion tank to 'MAX'
mark.
6.Connect battery earth lead.
M18 0764

ENGINE MANAGEMENT SYSTEM - SIEMENS
18-3-12 REPAIRS
Sensor - camshaft position (CMP)
$% 18.30.24
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Release CMP multiplug from bracket and
disconnect multiplug.
4.Remove bolt securing CMP sensor multiplug
bracket and release CMP sensor lead from
behind bracket.
5.Remove bolt securing CMP sensor to camshaft
cover.
6.Remove CMP sensor and discard seal.Refit
1.Clean CMP sensor and mating face.
2.Lubricate new seal with clean engine oil and fit
to CMP sensor.
3.Position CMP sensor, fit and tighten bolt to 8
Nm (6 lbf.ft).
4.Feed CMP sensor lead behind multiplug
bracket, align bracket, fit bolt and tighten to 8
Nm (6 lbf.ft).
5.Connect CMP sensor multiplug and secure to
bracket.
6.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
7.Connect battery earth lead.

ENGINE MANAGEMENT SYSTEM - SIEMENS
REPAIRS 18-3-13
Sensor - knock (KS)
$% 18.30.28
Remove
1.Disconnect battery earth lead.
2.Remove LH inlet manifold.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket - inlet
manifold - LH.
3.Disconnect KS multiplug.
4.Note the routing of each KS harness.
5.Remove 2 bolts securing KS to cylinder block
and remove sensors.
Refit
1.Clean KS and mating faces on cylinder block.
2.Position KS, ensure that harnesses are
correctly routed, fit and tighten bolts to 25 Nm
(18 lbf.ft).
3.Connect KS multiplug.
4.Fit LH inlet manifold.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket - inlet
manifold - LH.
5.Connect battery earth lead.
Switch - throttle pedal - Non NAS
$% 18.30.36
Remove
1.Remove 2 nuts securing throttle pedal
assembly to bulkhead.
2.Release clip securing throttle inner cable to
throttle pedal and disconnect inner cable from
pedal.
3.Disconnect multiplug from throttle pedal switch.
4.Remove throttle pedal assembly from vehicle.

ENGINE MANAGEMENT SYSTEM - SIEMENS
18-3-14 REPAIRS
5.Release throttle pedal switch from bracket on
throttle pedal assembly.
6.Release clips securing switch bracket to pedal
assembly and remove bracket.
Refit
1.Fit switch bracket to throttle pedal assembly
and secure with clips
2.Position switch and push fully into bracket on
pedal assembly.
3.To correctly position throttle pedal switch, move
throttle pedal to the closed position and ensure
that switch is in contact with tang on throttle
pedal.
4.Connect multiplug to throttle pedal switch.
5.Connect throttle inner cable to throttle pedal
and secure with clip.
6.Position throttle pedal assembly to bulkhead, fit
and tighten nuts to 25 Nm (18 lbf.ft).
Sensor - combined - manifold absolute
pressure/Intake air temperature (MAP/
IAT)
$% 19.22.26
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Disconnect multiplug from MAP/IAT sensor.
4.Remove 2 screws securing MAP/IAT sensor to
inlet manifold chamber, remove sensor.
Refit
1.Clean MAP/IAT sensor and mating face on inlet
manifold chamber.
2.Position MAP/IAT sensor, fit and tighten
screws.
3.Connect multiplug to MAP/IAT sensor.
4.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
5.Connect battery earth lead.
M19 3182
M19 3197

ENGINE MANAGEMENT SYSTEM - SIEMENS
REPAIRS 18-3-15
Sensor - throttle position (TP) - NAS - up
to 03MY
$% 19.22.49
Remove
1.Disconnect battery earth lead.
2.Remove 2 nuts and release throttle pedal from
studs.
3.Release TP sensor multiplug from bracket and
disconnect from main harness.
4.Remove nut and release lever from sensor.
5.Remove 2 nuts and bolts and remove sensor.Refit
1.Fit TP sensor and tighten nuts and bolts to 10
Nm (7 lbf.ft).
2.With throttle pedal held closed, fit lever to
sensor and tighten nut to 10 Nm (7 lbf.ft).
3.Position throttle pedal, connect multiplug and
secure to pedal bracket.
4.Fit pedal to studs and tighten nuts to 25 Nm (18
lbf.ft).
5.Connect battery earth lead.
6.Use TestBook/T4 to confirm correct operation.