gearbox LAND ROVER FREELANDER 2001 Repair Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 2001, Model line: FREELANDER, Model: LAND ROVER FREELANDER 2001Pages: 1007, PDF Size: 23.47 MB
Page 221 of 1007
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.
Page 223 of 1007
ENGINE - K SERIES KV6
12-3-46 REPAIRS
Engine mounting - LH
$% 12.45.11
Remove
1.Remove engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
2.Remove battery carrier.
+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
3.Using a hoist, connect adjustable lifting
bracket, LRT-12-138 to engine.
4.Raise hoist to take weight without exerting any
load on the engine mountings.
5.Remove through bolt securing LH engine
mounting to gearbox bracket.
6.Remove 4 bolts securing LH mounting to body
and remove mounting.Refit
1.Position LH mounting to body, fit and tighten
bolts to 48 Nm (35 lbf.ft).
2.Align gearbox bracket to LH body mounting, fit
and tighten through bolt to 100 Nm (74 lbf.ft).
3.Lower hoist, disconnect and remove lifting
bracket, LRT-12-138.
4.Fit battery carrier.
+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
5.Fit engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
M12 6599
Page 226 of 1007
ENGINE - K SERIES KV6
REPAIRS 12-3-49
Torque converter drive plate
$% 12.53.13
Remove
1.Remove automatic gearbox.
+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gearbox - KV6.
2.Assemble LRT-12-161 to LRT-12-199 and
secure with clamp bolt.
3.Position LRT-12-161 and LRT-12-199 to
crankshaft pulley to restrain crankshaft.
4.Remove and discard 6 Patchlok bolts securing
drive plate to crankshaft.
5.Remove drive plate from crankshaft.Refit
1.Clean bolt holes in crankshaft using an old
drive plate bolt with two saw cuts at an angle of
45° to the bolt shank.
2.Clean drive plate and mating face of
crankshaft.
3.Position LRT-12-161 and LRT-12-199 to
crankshaft pulley to restrain crankshaft.
4.Position drive plate to crankshaft.
5.Fit new Patchlok bolts securing drive plate to
crankshaft and tighten in sequence shown to:
lStage 1 - 25 Nm (18 lbf.ft)
lStage 2 - 100 Nm (74 lbf.ft)
6.Remove LRT-12-161 and LRT-12-199 from
crankshaft pulley.
7.Fit automatic gearbox.
+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gearbox - KV6.
Page 258 of 1007
ENGINE - K SERIES KV6
OVERHAUL 12-3-81
Crankshaft rear oil seal
$% 12.21.20.01
Remove
1.Remove automatic gearbox.
+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gearbox - KV6 - with engine and
gearbox removed.
2.Assemble LRT-12-161 to LRT-12-199 and
secure with clamp bolt.
3.Position LRT-12-161 and LRT-12-199 to
crankshaft pulley to restrain crankshaft.
4.With assistance, remove and discard 6 bolts
securing drive plate to crankshaft.
5.Remove drive plate from crankshaft.6.Remove and discard 5 bolts securing
crankshaft rear oil seal housing to cylinder
block.
7.Remove crankshaft rear oil seal.
Refit
1.Clean cylinder block face and oil seal running
surface on crankshaft, ensure bolt holes are
clean and dry.
2.Position oil seal protector, LRT-12-061 to
crankshaft.
3.Position oil seal to crankshaft.
CAUTION: Oil seal must be fitted dry.
Page 259 of 1007
ENGINE - K SERIES KV6
12-3-82 OVERHAUL
4.Fit new Patchlok bolts securing oil seal to
cylinder block and using sequence shown,
tighten to 8 Nm (6 lbf.ft).
5.Remove oil seal protector LRT-12-061.
6.Clean bolt holes in crankshaft using an old
drive plate bolt with two saw cuts at an angle of
45° to the bolt shank.
7.Clean drive plate and mating face of
crankshaft.
8.Position drive plate to crankshaft and fit but do
not tighten new Patchlok bolts.
9.Position LRT-12-161 and LRT-12-199 to
crankshaft pulley to restrain crankshaft.
10.Using sequence shown, tighten to bolts to:
lStage 1 - 25 Nm (18 lbf.ft)
lStage 2 - 100 Nm (74 lbf.ft)
11.Remove special tool from crankshaft pulley,
loosen bolt and remove LRT-12-161 from LRT-
12-199.
12.Fit automatic gearbox.
+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gearbox - KV6 - with engine and
gearbox removed.
Crankshaft
$% 12.21.33.01
Remove
1.Remove cylinder head gaskets.
+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - LH.
+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - RH.
2.Remove oil pump gasket.
+ ENGINE - K SERIES KV6,
OVERHAUL, Oil pump - Overhaul.
3.Remove crankshaft rear oil seal.
+ ENGINE - K SERIES KV6,
OVERHAUL, Crankshaft rear oil seal.
4.Remove engine sump.
+ ENGINE - K SERIES KV6,
OVERHAUL, Sump - engine oil.
Disassembly
1.Remove bolt securing oil pick up strainer,
remove strainer and discard 'O' ring.
Page 314 of 1007
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.
Page 345 of 1007
FUEL DELIVERY SYSTEM - PETROL
19-2-24 REPAIRS
Sensor - heated oxygen (H02S) - post
catalyst - LH - KV6 - Non NAS
$% 19.22.71
Remove
1.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.
2.Remove gear selector knob.
+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gear knob.
3.Release clips securing selector lever trim panel
to centre console and move trim panel aside.
4.Disconnect HO2S multiplug from harness.
5.Release grommet and withdraw HO2S harness
multiplug through grommet aperture.6.Remove HO2S.
Refit
1.Clean HO2S and mating face.
2.Fit HO2S and tighten to 55 Nm (41 lbf.ft) using
tool LRT-19-014.
3.Feed HO2S harness through grommet aperture
and secure grommet.
4.Connect HO2S multiplug.
5.Fit trim panel and gaiter to centre console and
secure clips.
6.Fit gear selector knob.
+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gear knob.
7.Remove stand(s) and lower vehicle.
Page 374 of 1007
MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-1
MANIF OLDS & EX HAUST SYSTEMS - K SERIES KV6 REPAIRS
Front pipe - Non NAS
$% 30.10.09
Remove
1.Remove gear selector knob.
+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gear knob.
2.Release clips securing selector lever trim panel
to centre console and move trim panel aside.
3.Release and disconnect post catalyst HO2S
multiplug.
4.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Release grommet and withdraw HO2S harness
multiplug through grommet aperture.6.Remove nut securing exhaust heat shield to
mounting bracket.
7.Remove 2 nuts securing heat shield to IRD
pinion housing.
8.Remove heat shield.
9.Remove 4 nuts securing front pipe flanges to
exhaust manifolds.
10.Release manifold flanges.
Page 375 of 1007
MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-2 REPAIRS
11.Remove 3 nuts securing front pipe to
intermediate pipe.
12.Release intermediate pipe from front pipe.
13.Remove gasket.
14.Remove exhaust front pipe.
15.Remove HO2S.Refit
1.Clean HO2S and mating face.
2.If refitting existing HO2S, apply anti-seize
compound to HO2S threads.
3.Fit HO2S and tighten to 55 Nm (41 lbf.ft)using
tool LRT-19-014.
4.Clean exhaust pipe and manifold flanges.
5.Fit exhaust front pipe.
6.Using new gasket, connect intermediate pipe to
front pipe, fit nuts and tighten to 50 Nm (37
lbf.ft).
7.Position LH exhaust manifold flange to front
pipe, fit and tighten nuts to 50 Nm (37 lbf.ft).
8.Position RH exhaust manifold flange to front
pipe, fit and tighten nuts to 50 Nm (37 lbf.ft).
9.Fit exhaust heatshield and fit nuts finger tight.
10.Tighten nut securing exhaust heatshield to
exhaust mounting bracket to 45 Nm (33 lbf.ft).
11.Tighten nuts securing exhaust heatshield to
pinion housing to 25 Nm (18 lbf.ft).
12.Feed HO2S harness through grommet aperture
and secure grommet.
13.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
14.Connect HO2S multiplug.
15.Fit trim panel and gaiter to centre console and
secure clips.
16.Fit gear selector knob.
+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gear knob.
Page 404 of 1007
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.