wheel LAND ROVER FREELANDER 2001 Repair 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 - K SERIES KV6
12-3-54 REPAIRS
10.Using a mallet, gently tap sump sideways to
break sealant bond, remove sump.
CAUTION: Do not lever between sump and
lower crankcase.
Refit
1.Using a suitable cleaning solvent, clean sump
and mating face on lower crankcase. DO NOT
use a metal scraper on sealing surfaces.
2.Apply a 2 mm (0.1 in) bead of sealant, Part No.
STC 4600 along centre of sump flange, then
spread to an even film using a roller.
CAUTION: To avoid contamination,
assembly must be completed immediately
after application of sealant.
3.Position sump, fit bolts and tighten
progressively in the sequence shown to 35 Nm
(26 lbf.ft).
4.Fit bolts securing IRD support bracket to sump
and tighten to 88 Nm (65 lbf.ft).
5.Position engine oil cooler to mounting bracket,
fit and tighten nuts to 25 Nm (18 lbf.ft).
6.Position dipstick tube to sump and cylinder
block, fit bolt and tighten to 9 Nm (7 lbf.ft).
7.Fit splash shield and secure with bolts.
8.Fill engine with correct quantity and grade of oil.

+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.
9.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
10.Connect battery earth lead.
Switch - oil pressure
$% 12.60.50
Remove
1.Disconnect battery earth lead.
2.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Remove RH front road wheel.
4.Remove 3 bolts securing RH splash shield to
body and remove shield.
5.Place container below oil pressure switch to
collect spillage.
6.Disconnect multiplug from oil pressure switch.
7.Remove oil pressure switch and discard
sealing washer.
M12 6675
10
9
135
8
4
7
26
M12 6614

ENGINE - K SERIES KV6
REPAIRS 12-3-55
Refit
1.Ensure oil pressure switch and mating face is
clean.
2.Fit oil pressure switch using a new sealing
washer and tighten to 14 Nm (10 lbf.ft).
3.Connect multiplug to oil pressure switch.
4.Remove oil container from underneath of
engine.
5.Fit splash shield and secure with bolts.
6.Fit RH road wheel and tighten nuts to 115 Nm
(85 lbf.ft).
7.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
8.Check engine oil level, top-up if necessary.
9.Connect battery earth lead.
Oil pressure relief valve
$% 12.60.56
Remove
1.Disconnect battery earth lead.
2.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Remove RH front road wheel.
4.Remove 3 bolts securing RH splash shield to
body and remove shield.
5.Place suitable container under oil filter to collect
spillage.
6.Using strap wrench, remove and discard oil
filter.
M12 6614
M12 6660

ENGINE - K SERIES KV6
12-3-56 REPAIRS
7.Remove 4 nuts securing engine oil cooler to
mounting bracket and position oil cooler aside.
8.Remove oil pressure relief valve plug nut.
Note: If a hexagonal head plug and sealing
washer are fitted, discard sealing washer.
9.Remove spring and valve.Refit
1.Clean valve, spring and plug; remove all traces
of sealant from threads in oil pressure relief
valve bore and from threads of plug.
CAUTION: Do not use a tap.
2.Clean valve seating inside oil pump housing.
3.Check that valve slides freely in bore and that
valve and bore are free from scoring and
corrosion.
Note: Light corrosion may be removed using
grade 600 emery cloth soaked in oil.
4.Check free length of spring.

+ GENERAL DATA, Engine - KV6
Petrol.
5.Apply sealant, Part No. STC 50552 to plug
threads.
Note: If a hexagonal head plug and sealing
washer were fitted, fit new sealing washer to
plug.
6.Fit valve, spring and plug to oil pump housing.
Tighten plug to 25 Nm (18 lbf.ft).
7.Fill canister of replacement oil filter with clean
engine oil.
8.Lubricate new oil filter seal with clean engine oil
and fit filter.
9.Position engine oil cooler to mounting bracket,
fit and tighten nuts to 25 Nm (18 lbf.ft).
10.Remove oil container from underneath of
engine.
11.Fit splash shield and secure with bolts.
12.Fit RH road wheel and tighten nuts to 115 Nm
(85 lbf.ft).
13.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
14.Connect battery earth lead.
15.Check engine oil level, top-up if necessary.
M12 7916

ENGINE - K SERIES KV6
REPAIRS 12-3-57
Oil cooler - engine
$% 12.60.68
Remove
1.Disconnect battery earth lead.
2.Drain cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
3.Remove RH front road wheel.
4.Remove 3 bolts securing RH splash shield to
body and remove shield.
5.Position container to collect spillage under oil
filter.
6.Loosen and remove oil cooler pipe unions from
oil filter housing, remove and discard 2 'O'
rings.
CAUTION: Failure to retain bosses will
result in damage to oil cooler. Always fit
plugs to open connections to prevent
contamination.
7.Position container to collect coolant spillage.8.Release clips and disconnect coolant hoses
from engine oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
9.Remove 4 nuts securing engine oil cooler to
mounting bracket and remove oil cooler.
10.Restrain oil cooler pipe bosses on oil cooler
housing, loosen and remove oil cooler pipes
from oil cooler; remove and discard 2 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
Refit
1.Clean oil cooler pipe unions and mating faces.
2.Lubricate new 'O' rings with clean engine oil
and fit to oil cooler pipes.
3.Fit pipes to engine oil cooler, restrain bosses on
oil cooler body and tighten unions to 26 Nm (19
lbf.ft).
CAUTION: To prevent damage to
components, use two spanners when
loosening or tightening unions.
4.Position engine oil cooler to mounting bracket,
fit and tighten nuts to 25 Nm (18 lbf.ft).
5.Position oil cooler pipes to oil filter housing and
tighten unions to 26 Nm.
6.Connect coolant hoses to oil cooler and secure
with clips.
7.Fit splash shield and secure with bolts.
8.Fit RH road wheel and tighten nuts to 115 Nm
(85 lbf.ft).
9.Fill cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
10.Connect battery earth lead.
11.Check engine oil level and top-up if necessary.
M12 6614
M12 7917

ENGINE - K SERIES KV6
12-3-58 REPAIRS
Camshaft timing belt
$% 12.65.18
Remove
1.Disconnect battery earth lead.
2.Remove ancillary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - KV6.
3.Remove RH front road wheel.
4.Remove 3 bolts securing RH splash shield to
body and remove shield.
5.Remove 3 bolts securing camshaft timing belt
LH rear cover and remove cover.
6.Remove inlet manifold chamber.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - from 03MY.7.Remove 2 bolts securing RH rear timing belt
cover heat shield; remove heat shield.
8.Remove 3 bolts securing RH rear timing belt
cover; remove cover.
9.Using a socket on crankshaft pulley bolt, rotate
crankshaft in a clockwise direction. Align the
engine "SAFE" position, notch on crankshaft
pulley with the "ARROW" on front mounting
plate and the timing marks aligned on the rear
camshaft gears as illustrated.
CAUTION: Do not use camshaft gear bolts
or timing belt to rotate crankshaft.
M12 6614
M12 6694

ENGINE - K SERIES KV6
12-3-66 REPAIRS
40.Fit bolt and nut and bolt securing alternator to
front mounting plate and tighten to 45 Nm (33
lbf.ft).
41.Connect alternator multiplug.
42.Connect battery lead to alternator, fit and
tighten nut to 8 Nm (6 lbf.ft), fit terminal cover.
43.Position PAS pump to front mounting plate, fit
and tighten bolts to 25 Nm (18 lbf.ft).
44.Position PAS pipe to engine front mounting
plate, fit and tighten bolt to 25 Nm (18 lbf.ft).
45.Clean PAS pump pulley mating faces.
46.Position PAS pump pulley, fit and tighten Torx
screws to 9 Nm (7 lbf.ft).
47.Position lower engine steady to sump
mounting, fit and tighten bolt to 100 Nm (74
lbf.ft).
48.Tighten bolt securing lower engine steady to
subframe to 100 Nm (74 lbf.ft).
49.Clean LH rear timing belt cover.
50.Position LH rear timing belt cover, fit and
tighten bolts to 4 Nm (3 lbf.ft).
51.Clean RH rear timing belt cover.
52.position RH rear timing belt cover, fit bolts and
tighten to 4 Nm (3 lbf.ft).
53.Position heat shield, fit bolts and tighten M6 bolt
to 9 Nm (7 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).
54.Fit inlet manifold chamber.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - from 03MY.
55.Fit RH road wheel and tighten nuts to 115 Nm
(85 lbf.ft).
56.Fit ancillary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - KV6.
Camshaft timing belt cover - RH front
$% 12.65.39
Remove
1.Disconnect battery earth lead.
2.Remove ancillary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - KV6.
3.Remove 3 bolts securing camshaft timing belt
RH front cover and remove cover.
Refit
1.Clean RH front timing belt cover.
2.Position RH front timing belt cover, fit and
tighten bolts to 4 Nm (3 lbf.ft).
3.Fit ancillary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - KV6.
4.Connect battery earth lead.

ENGINE - K SERIES KV6
REPAIRS 12-3-69
Camshaft rear timing belt - LH cylinder
head
$% 12.65.56
Remove
1.Disconnect battery earth lead.
2.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Remove LH rear timing belt cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt cover - LH rear.
4.Remove RH front road wheel.
5.Remove 3 bolts securing RH splash shield to
body and remove shield.6.Using a socket on crankshaft pulley bolt, rotate
crankshaft in a clockwise direction. Align the
engine "SAFE" position, notch on crankshaft
pulley aligned to the "ARROW" on front
mounting plate and the timing marks aligned on
the rear camshaft gears as illustrated.
CAUTION: Do not use camshaft gear bolts
or timing belt to rotate crankshaft. Never
use the arrow on the oil pump body as a
timing reference.
7.Insert timing pin LRT-12-232 through hole in
lower crankcase, ensuring pin is located in hole
in drive plate.
CAUTION: Hole immediately adjacent to
side of lower crankcase must be used.
M12 6614
LRT-12-232
M12 7927

ENGINE - K SERIES KV6
12-3-72 REPAIRS
9.Position LRT-12-197 into the front end of the
LH exhaust camshaft.
10.With assistance, using a 30 mm socket on LRT-
12-197, turn the LH 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 LH 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 LH rear timing belt cover.

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

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