exhaust LAND ROVER FREELANDER 2001 Repair Manual

ENGINE - K SERIES KV6
OVERHAUL 12-3-103
25.Fit LRT-12-198 alignment pins into the end of
each camshaft.
26.Position timing belt and gears over LRT-12-198
and locate gears onto camshafts.
27.Position LRT-12-197 into the front end of the
exhaust camshaft.
28.With assistance, using a 30 mm socket on LRT-
12-197, turn the exhaust camshaft sufficiently
to align camshaft gears to the drive slots in
each camshaft.29.Remove LRT-12-198 alignment pins and fit
new camshaft gear retaining bolts.
30.Tighten camshaft gear bolts to:
lStage 1 - 27 Nm (20 lbf.ft)
lStage 2 - Further 90°
31.Remove LRT-12-175 from camshaft gears.
32.Remove LRT-12-197 from front end of exhaust
camshaft.
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.
33.Fit timing belt rear cover and tighten bolts to 9
Nm (7 lbf.ft).
Refit
1.Fit cylinder head gaskets.

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

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

ENGINE - K SERIES KV6
12-3-108 OVERHAUL
4.Remove Torx screw securing idler pulley to
front mounting plate and remove pulley.
5.Release alternator battery lead terminal cover,
loosen terminal nut and disconnect lead from
terminal
6.Disconnect multiplug from alternator.
7.Remove lower bolt and upper nut and bolt
securing alternator to front mounting plate.
8.Release alternator and remove.9.Remove 3 bolts securing camshaft timing belt
LH rear cover and remove cover.
10.Remove inlet manifold chamber - if fitted.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.
11.Remove 2 bolts securing RH rear timing belt
cover heat shield to cylinder head; remove heat
shield.
12.Remove 3 bolts securing RH rear timing belt
cover; remove cover.
M12 6694

ENGINE - K SERIES KV6
OVERHAUL 12-3-111
27.Remove 5 bolts and 2 pillar bolts securing
engine front mounting plate to cylinder block.
28.Remove 2 bolts securing IRD support bracket
to engine front mounting plate.
29.With care, release and remove front mounting
plate from engine.
30.Fit a suitable 1.5 mm diameter pin through hole
in tensioner body and into hole in plunger.
NOTE: If holes in body and plunger are not
aligned, move tensioner backplate using a
broad bladed screwdriver; this will move the
plunger sufficiently to align the holes and allow
the pin to be inserted.31.Remove and discard 2 Patchlok bolts securing
tensioner to cylinder block and remove
tensioner.
CAUTION: Exercise great care when
removing bolts, do not apply excessive
torque. If bolts appear to be seized, apply
suitable anti-seize lubricant prior to
removing bolts. DO NOT loosen Allen screw
securing tensioner pulley.
32.If camshaft timing belt is to be refitted, mark
direction of rotation on timing belt before
removal.
33.With care, ease camshaft timing belt from
gears using fingers only and remove timing
belt.
CAUTION: Do not rotate crankshaft or
camshafts with timing belt removed.
CAUTION: Camshaft timing belt must be
replaced if cylinder head is to be removed or
new drive gears, tensioner or coolant pump
are to be fitted. 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.
34.Remove and discard LH and RH exhaust
camshaft cap seals.

ENGINE - K SERIES KV6
12-3-112 OVERHAUL
35.Position tools LRT-12-196 to LH and RH front
inlet camshaft gears and into the end of each
exhaust camshaft.
CAUTION: Special tools must be fitted when
tightening or loosening gear retaining bolts,
otherwise damage to camshafts may occur.
36.Remove and discard bolts retaining front inlet
camshaft gears to camshafts.
37.Remove tools LRT-12-196 from both inlet
camshaft gears and exhaust camshafts.
38.Remove camshaft drive gears and hub
assemblies.
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 hubs, crankshaft
gear, tensioner and water pump pulleys.
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.
2.Fit hubs to camshaft gears and fit gears to
camshafts.
3.Fit new camshaft gear bolts; tighten bolts
sufficiently to allow gears to rotate without
tipping.4.Position timing belt to crankshaft gear.
NOTE: To prevent the timing belt from
disengaging from the crankshaft gear when
fitting, fit a suitable wedge between the belt and
oil pump belt guard.
5.Fit tool LRT-12-197 into each exhaust
camshaft in turn.
6.Using assistance, rotate each exhaust
camshaft slightly and align timing marks on LH
and RH rear camshaft gears.
7.Remove tool LRT-12-197.
8.Fit tools LRT-12-175 to LH and RH rear
camshaft gears.
9.Rotate both front camshaft gears fully
clockwise as viewed from front of engine.
10.Using fingers only, fit timing belt to gears,
starting at the crankshaft gear and working in
an anti-clockwise direction, keeping the belt run
as taut as possible and turning the camshaft
gears only a minimum amount anti-clockwise to
fit timing belt.
CAUTION: Gears must not be rotated anti-
clockwise more than one tooth.

ENGINE - K SERIES KV6
OVERHAUL 12-3-113
11.Position an Allen key in tensioner backplate
and hold tensioner pulley against timing belt.
12.With assistance, position timing belt tensioner,
fit new Patchlok bolts and tighten to 25 Nm (18
lbf.ft).
CAUTION: Ensure tensioner plunger is
contacting underside of tensioner
backplate.
13.Remove tools LRT-12-175 from rear timing belt
gears.
14.Fit tools LRT-12-196 to both front inlet
camshaft gears and into the end of each
exhaust camshaft.
CAUTION: Special tools must be fitted when
tightening or loosening gear retaining bolts,
otherwise damage to camshafts may occur.
15.Tighten front inlet camshaft gear bolts to:
lStage 1 - 27 Nm (20 lbf.ft)
lStage 2 - Further 90°
16.Remove tools LRT-12-196 from both inlet
camshaft gears and exhaust camshafts.17.Remove wedge from between drive belt and oil
pump belt guard.
18.Remove 1.5 mm diameter pin from tensioner.
19.Clean exhaust camshaft front cap seal
locations and fit new cap seals.
CAUTION: The sealing edge of the cap seal
and mating face must be clean and dry.
20.Position engine front mounting plate and
manoeuvre plate into position; fit bolts but do
not tighten at this stage.
21.Fit bolts securing IRD support bracket to front
mounting plate; do not tighten bolts at this
stage.
22.Tighten bolts in the sequence shown:
lM10 bolt - No.1 - 25 Nm (18 lbf.ft)
lM10 bolt - No. 5 - 45 Nm (33 lbf.ft)
lBolts Nos. 2, 3, 4, 6 and 7 - 85 Nm (63 lbf.ft)
23.Position engine lifting bracket, fit bolts securing
lifting bracket and front mounting plate to
cylinder block and RH cylinder head and
tighten to:
lM8 bolt - 25 Nm (18 lbf.ft)
lM10 bolts - 45 Nm (33 lbf.ft)
24.Fit rubber blanking plug around tensioner.
25.Clean end of dipstick tube.
26.Position dipstick tube to sump and cylinder
block, fit bolt and tighten to 9 Nm (7 lbf.ft).
27.Clean lower timing belt cover.
28.Position lower timing belt cover, fit and tighten
bolts to 9 Nm (7 lbf.ft).
29.Remove timing pin LRT-12-232.
30.Clean crankshaft pulley.
31.Fit crankshaft pulley to crankshaft gear and
ensure that the indent on pulley locates over
the lug on crankshaft gear.
32.Fit crankshaft pulley bolt and washer, position
LRT-12-161 with LRT-12-199 into crankshaft
pulley. Tighten pulley bolt to 160 Nm (118
lbf.ft).
33.Remove tools LRT-12-161 and LRT-12-199.
34.Clean ancillary drive belt tensioner.

ENGINE - K SERIES KV6
12-3-114 OVERHAUL
35.Position ancillary belt tensioner, fit bolts and
tighten to 25 Nm (18 lbf.ft).
36.Clean LH and RH front timing belt covers.
37.Position LH and RH front timing belt covers, fit
and tighten bolts to 4 Nm (3 lbf.ft).
38.Clean idler pulley, position pulley to engine
front mounting plate and tighten Torx bolt to 45
Nm (33 lbf.ft).
39.Position alternator to front mounting plate.
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.Clean LH rear timing belt cover.
44.Position LH rear timing belt cover, fit and
tighten bolts to 4 Nm (3 lbf.ft).
45.Clean RH rear timing belt cover.
46.Position RH rear timing belt cover, fit bolts and
tighten to 4 Nm (3 lbf.ft).
47.Position heat shield, fit bolts and tighten M6 bolt
to 9 Nm (7 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).
48.Fit inlet manifold chamber - if fitted.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.
49.Position ancillary drive belt to crankshaft and
alternator pulleys.
50.Position engine mounting front bracket to
engine front plate and tighten bolts to 45 Nm
(33 lbf.ft).

EMISSION CONTROL
17-1-8 REPAIRS
Solenoid/modulator valve - EGR - Td4
$% 17.45.04
Remove
1.Disconnect battery earth lead.
2.Remove inlet manifold gaskets.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Gaskets - induction
manifold.
3.Disconnect multiplug from EGR solenoid valve.
4.Remove 2 bolts securing EGR solenoid bracket
to cylinder block.
5.Identify and disconnect vacuum hoses.
6.Remove 2 nuts and remove EGR solenoid
valve from bracket.Refit
1.Fit EGR solenoid valve to bracket and secure
with nuts.
2.Position EGR solenoid valve, identify and
connect vacuum hoses and tighten bolts to 10
Nm (7.5 lbf.ft).
3.Connect multiplug to EGR solenoid valve.
4.Fit inlet manifold gaskets.
+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Gaskets - induction
manifold.
5.Connect battery earth lead.

EMISSION CONTROL
REPAIRS 17-1-9
Thermal valve - exhaust gas
recirculation (EGR) - Td4 Automatic
transmission (hot climates) - from 03 MY
$% 17.45.07
Remove
1.Disconnect the battery earth lead.
2.Release thermal valve coolant hose from clips.
3.Position container to collect coolant.
4.Release 3 clips securing coolant hoses to the
EGR thermal valve.
5.Disconnect coolant hoses from the EGR
thermal valve and remove the thermal valve.
Refit
1.Position the EGR thermal valve and connect
coolant hoses.
2.Secure hoses with clips.
3.Fit thermal valve coolant hose into clips.
4.Connect the battery earth lead.
5.Refill the cooling system.

+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.
Cooler - EGR - Td4
$% 17.45.40
Remove
1.Disconnect battery earth lead.
2.Remove camshaft cover.

+ ENGINE - Td4, REPAIRS, Gasket -
camshaft cover.
3.Mark EGR pipe and cooler to aid refit.
4.Loosen clamps EGR pipes to cooler and move
clamps aside.
5.Remove pipe, EGR cooler to EGR valve.
6.Remove bolt securing fuel rails to support
bracket.
7.Remove bolt securing turbocharger outlet pipe
to support bracket.
8.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
M170364

M17 0283

EMISSION CONTROL
17-1-12 REPAIRS
Filter - fuel leak detection pump - KV6 -
NAS
$% 17.45.42
Remove
1.Disconnect battery earth lead.
2.Remove RH rear wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
3.Remove nut and release filter from bracket.
4.Release clip and remove filter from pipe.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
Refit
1.Fit filter to pipe and secure with clip.
2.Fit filter to bracket and tighten nut to 3 Nm (2.2
lbf.ft).
3.Fit wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
4.Connect battery earth lead.
Catalytic converter - RH - KV6 - NAS
$% 17.50.01
Remove
1.Position vehicle on 4 post ramp.
2.Disconnect battery earth lead.
3.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
4.Release pre catalyst H02S harness from clips.
5.Release and disconnect HO2S multiplug.
6.Remove intermediate pipe and silencer.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Intermediate
pipe - NAS.
7.Remove 3 bolts and remove LH heat shield.
M19 3484

EMISSION CONTROL
REPAIRS 17-1-13
8.Remove 2 bolts and remove RH heat shield.
9.Release post catalyst HO2S harness from
clips.
10.Release and disconnect post catalyst HO2S
multiplug.
11.Remove 2 bolts securing pipe clamp and
remove clamp.12.Remove 2 nuts securing catalyst, remove
catalyst and discard gasket.
NOTE: Do not carry out further dismantling if
component is removed for access only.
13.Identify and remove both H02S from catalyst.
Refit
1.Clean H02S and mating faces.
2.Fit both H02S and tighten to 55 Nm (40 lbf.ft).
3.Clean catalyst and mating face.
4.Using a new gasket, fit catalyst and fit nuts but
do not tighten at this stage.
5.Fit clamp, fit bolts but do not tighten at this
stage.
6.Connect post catalyst H02S multiplug and fit to
bracket.
7.Fit harness into clips.
8.Fit heat shields and tighten bolts to 10 Nm (7
lbf.ft).
9.Fit intermediate pipe and silencer.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Intermediate
pipe - NAS.
10.Tighten nuts securing catalyst to manifold to 50
Nm (37 lbf.ft).
11.Tighten bolts securing clamp to 10 Nm (7 lbf.ft).
12.Connect pre catalyst H02S multiplug and fit to
bracket.
13.Fit harness into clips.
14.Fit acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
15.Connect battery earth lead.
M19 3482