timing belt LAND ROVER FREELANDER 2001 Service Manual

ENGINE - K SERIES KV6
12-3-74 REPAIRS
8.Remove and discard RH front exhaust
camshaft cap seal from cylinder head.
9.Position LRT-12-175 to rear camshaft gears as
illustrated, remove and discard bolts securing
gears to camshafts.
10.Remove rear camshaft gears, timing belt and
special tool as an assembly.
CAUTION: Do not turn the crankshaft or the
camshafts while the timing belt is removed.
11.If camshaft timing belt is to be refitted, mark
direction of rotation on timing belt.12.Remove LRT-12-175 from camshaft gears and
remove timing belt from gears.
CAUTION: 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.

ENGINE - K SERIES KV6
REPAIRS 12-3-75
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 mating faces on
camshafts.
CAUTION: If the sintered gears have been
subjected to prolonged oil contamination,
they must be soaked in a solvent bath 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 belt.
2.Place gears inverted on a flat surface, with the
locating lugs on the gears positioned as
illustrated.3.Keeping the timing marks aligned, position
timing belt onto gears.
4.Position LRT-12-195 between the gears, turn
centre nut sufficiently to spread drive belt.
5.Invert gears and timing belt and position LRT-
12-175 to camshaft gears.
6.Check that the locating lugs are correctly
aligned and remove LRT-12-195 from between
camshaft gears.

ENGINE - K SERIES KV6
12-3-76 REPAIRS
7.Fit LRT-12-198 alignment pins into the end of
each camshaft.
8.Position timing belt and gears over LRT-12-198
and locate gears onto camshafts.
9.Position LRT-12-197 into the front end of the
RH exhaust camshaft.
10.With assistance, using a 30 mm socket on LRT-
12-197, turn the RH exhaust camshaft
sufficiently to align camshaft gears to the drive
slots in each camshaft.11.Remove LRT-12-198 alignment pins and fit
new camshaft gear retaining bolts.
12.Tighten camshaft gear bolts to:
lStage 1 - 27 Nm (20 lbf.ft)
lStage 2 - Further 90°
13.Remove LRT-12-175 from camshaft gears.
14.Remove LRT-12-197 from front end of exhaust
camshaft.
15.Clean RH exhaust camshaft cap seal recess
and fit new cap seal.
16.Remove timing pin LRT-12-232 from lower
crankcase.
17.Fit splash shield and secure with bolts.
18.Fit RH road wheel and tighten nuts to 115 Nm
(85 lbf.ft).
19.Fit RH rear timing belt cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt cover - RH rear.
20.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
21.Connect battery earth lead.

ENGINE - K SERIES KV6
12-3-80 OVERHAUL
Crankshaft front oil seal
$% 12.21.14.01
Remove
1.Remove camshaft timing belt.

+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.
2.Remove crankshaft drive gear.
3.Fit thrust button, LRT-12-200/3 to end of
crankshaft.
4.Screw LRT-12-200 into crankshaft front oil
seal.
5.Tighten centre bolt of LRT-12-200 to remove oil
seal.
6.Remove and discard oil seal from LRT-12-200.
7.Remove thrust button from crankshaft.Refit
1.Clean oil seal recess in oil pump and running
surface on crankshaft, ensure bolt holes are
clean and dry.
2.Fit oil seal guide from seal kit, over end of
crankshaft.
3.Position new seal on crankshaft up against oil
pump housing. Drift seal into place using tool
LRT-12-202.
CAUTION: Oil seal must be fitted dry.
4.Remove LRT-12-202 and oil seal guide from
crankshaft.
5.Clean crankshaft gear and wipe end of
crankshaft.
6.Fit drive gear to crankshaft.
7.Fit camshaft timing belt.

+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.

ENGINE - K SERIES KV6
OVERHAUL 12-3-87
Refit
1.Fit oil pump gasket.

+ ENGINE - K SERIES KV6,
OVERHAUL, Oil pump - Overhaul.
2.Fit engine sump.

+ ENGINE - K SERIES KV6,
OVERHAUL, Sump - engine oil.
3.Fit crankshaft rear oil seal.

+ ENGINE - K SERIES KV6,
OVERHAUL, Crankshaft rear oil seal.
4.Rotate crankshaft until timing pin LRT-12-232
can be inserted through hole immediately
adjacent to side of lower crankcase and into
elongated hole in drive plate.
CAUTION: Ensure that pin is in elongated
hole. Do not use cast arrow on oil pump
body as a timing mark. Do not remove
timing pin until timing belts are fitted.
5.Fit cylinder head gaskets.

+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - LH.

+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - RH.
Cylinder head gasket - LH
$% 12.29.02.01
Remove
1.Remove and discard camshaft timing belt.

+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.
2.Remove inlet manifold chamber.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, OVERHAUL, Seals -
manifold chamber - up to 03MY.
3.Remove 4 bolts securing LH front camshaft
timing belt cover backplate to cylinder head and
remove backplate.
4.Release HO2S lead from clip on cylinder block.
5.Using sequence shown, loosen then remove 4
nuts securing exhaust manifold to cylinder
head. Remove manifold, remove and discard
gasket.
6.Remove LH camshaft cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - LH - Up to 03MY.
LRT-12-232
M12 7927

ENGINE - K SERIES KV6
12-3-90 OVERHAUL
10.Tighten cylinder head bolts progressively in the
sequence shown to:
lStage 1 - 25 Nm (18 lbf.ft)
lStage 2 - 25 Nm (18 lbf.ft)
lStage 3 - 25 Nm (18 lbf.ft)
lStage 4 - Using an angle torque gauge,
tighten a bolts in same sequence a further
180°
11.Fit LH camshaft cover gasket.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - LH - Up to 03MY.
12.Remove and discard '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.
16.Position injector protection cover - if fitted to RH
fuel rail and secure injector harness to
protection cover or fuel rail with clips.
17.Fit bolts securing fuel rail to inlet manifolds and
tighten to 9 Nm (7 lbf.ft).
18.Connect coolant bleed hose to inlet manifold
and secure with clip.
19.Connect breather hose to LH inlet manifold.
20.Position ignition coils to LH inlet manifold.
21.Position earth lead, fit nuts and bolts securing
ignition coils to LH inlet manifold and tighten to
9 Nm (7 lbf.ft).
22.Clean camshaft drive belt cover backplate bolts
and apply sealant, Part No. STC 50552 to first
3 threads.
23.Position backplate, fit and tighten bolts to 9 Nm
(7 lbf.ft).
24.Clean exhaust manifold and cylinder head
mating face.25.Fit new exhaust manifold gasket. Position
exhaust manifold, fit nuts and using sequence
shown, tighten to 45 Nm (33 lbf.ft).
26.Secure HO2S lead in clip on cylinder block.
27.Connect HO2S multiplug and secure to support
bracket.
28.Fit new camshaft timing belt.

+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.

ENGINE - K SERIES KV6
OVERHAUL 12-3-91
Cylinder head gasket - RH
$% 12.29.03.01
Remove
1.Remove inlet manifold chamber.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, OVERHAUL, Seals -
manifold chamber - up to 03MY.
2.Remove and discard camshaft timing belt.

+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.
3.Release RH HO2S multiplug from coolant rail
bracket and disconnect multiplug.
4.Using sequence shown, loosen then remove 4
nuts securing RH exhaust manifold to cylinder
head.
5.Remove exhaust manifold, remove and discard
gasket.6.Remove 4 bolts securing RH front timing belt
cover backplate to cylinder head and remove
backplate.
7.Remove RH camshaft cover gasket.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - RH.
8. Up to 03MY: Remove 3 nuts and 3 bolts
securing ignition coils to LH inlet manifold and
release coil earth lead.
9. Up to 03MY:Remove ignition coils and position
aside.
M30 0996

ENGINE - K SERIES KV6
12-3-94 OVERHAUL
16.Position injector protection cover - if fitted to RH
fuel rail and secure injector harness to
protection cover or fuel rail with clips.
17.Fit bolts securing fuel rail to inlet manifolds and
tighten to 9 Nm (7 lbf.ft).
18.Connect coolant bleed hose to inlet manifold
and secure with clip.
19. Up to 03MY:Position ignition coils to LH inlet
manifold.
20. Up to 03MY:Position earth lead, fit nuts and
bolts securing ignition coils to LH inlet manifold
and tighten to 9 Nm (7 lbf.ft).
21.Clean camshaft timing belt cover backplate
bolts and apply sealant, Part No. STC 50552 to
the first 3 threads.
22.Position backplate, fit and tighten bolts to 9 Nm
(7 lbf.ft).
23.Fit new camshaft timing belt.

+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.
24.Clean exhaust manifold and mating face on
cylinder head.
25.Fit new exhaust manifold gasket. Position
exhaust manifold, fit nuts and using sequence
shown, tighten to 45 Nm (33 lbf.ft).
26.Connect RH HO2S multiplug, secure multiplug
in coolant rail bracket.
Cylinder head - decarbonise
$% 12.29.19
Remove
1.Remove cylinder head gaskets.

+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - LH.

+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - RH.
Disassembly
1. LH Cylinder head: Remove 3 bolts securing
LH rear timing belt cover and remove cover.
2. RH Cylinder head: Remove 2 bolts securing
RH rear timing belt cover heat shield to cylinder
head.
3. RH Cylinder head:Remove 3 bolts securing
RH rear timing belt cover; remove cover.
M12 6880
M12 6694

ENGINE - K SERIES KV6
OVERHAUL 12-3-95
4.Position LRT-12-175 to rear camshaft gears as
illustrated, remove and discard bolts securing
gears to camshafts.
5.Remove rear camshaft gears, timing belt and
LRT-12-175 as an assembly.
6.Remove LRT-12-175 from camshaft gears and
remove timing belt from gears. Discard timing
belt.
7.Remove spark plugs.
8.Remove and discard exhaust camshaft cap
seal from cylinder head.
Note: RH cylinder head illustrated.9.Progressively loosen then remove 7 bolts
securing inlet manifold to cylinder head,
remove inlet manifold and discard gasket.
10.Remove 4 bolts securing camshaft front timing
belt cover backplate to cylinder head and
remove backplate.
Note: LH backplate illustrated.
11.Remove 2 bolts securing camshaft rear timing
belt cover backplate to cylinder head and
remove backplate.
Note: LH backplate illustrated.
M12 6882
M12 6883

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.