lock LAND ROVER FREELANDER 2001 Manual PDF

ENGINE - K SERIES KV6
REPAIRS 12-3-45
Arm assembly - engine mounting RH
$% 12.45.06
Remove
1.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
2.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Remove bolt securing upper RH engine steady
to top arm.
4.Loosen bolt securing upper RH engine steady
to body, pivot engine steady away from top
arm.
5.Fit wooden block to jack, position jack under
engine sump to support engine.
6.Remove nut and 4 bolts securing engine top
arm bracket to RH hydramount and to engine
front mounting bracket.
7.Release PAS pipe support bracket from
hydramount and position pipe aside.
8.Remove top arm.Refit
1.Position top arm to front engine mounting
bracket, fit and tighten bolts to 100 Nm (74
lbf.ft).
2.Lower and remove jack supporting engine.
3.Position PAS pipe support bracket to
hydramount.
4.Fit nut securing top arm to RH hydramount and
tighten to 85 Nm (63 lbf.ft).
5.Position upper RH engine steady to top arm, fit
and tighten bolt to 100 Nm (74 lbf.ft).
6.Tighten bolt securing upper RH engine steady
to body to 100 Nm (74 lbf.ft).
7.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
8.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
M12 6605

ENGINE - K SERIES KV6
REPAIRS 12-3-51
Gasket - oil pump
$% 12.60.25
Remove
1.Disconnect battery earth lead.
2.Drain engine oil.

+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.
3.Remove camshaft timing belt.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
4.Remove crankshaft gear.
5.Disconnect multiplug from oil pressure switch.
6.Loosen and remove oil cooler pipe unions from
oil filter housing, remove and discard 2 'O'
rings.
7.Using strap wrench, remove and discard oil
filter.8.Using sequence shown, remove and discard 16
bolts securing oil pump to cylinder block.
9.Remove oil pump.
10.Remove and discard oil pump gasket.
11.Remove and discard crankshaft front oil seal
from oil pump housing.

ENGINE - K SERIES KV6
12-3-52 REPAIRS
Refit
1.Clean oil pump and mating face on cylinder
block ensure bolt holes are clean and dry.
2.Clean oil seal recess in oil pump and running
surface on crankshaft.
3.Fit new oil pump gasket, dry, to cylinder block.
4.Fit oil seal guide, from seal kit, over end of
crankshaft.
5.Position oil pump, aligning flats on oil pump
drive to flats on crankshaft. Fit new Patchlok
bolts and tighten progressively in sequence
shown to:
lStage 1 - 5 Nm (4 lbf.ft)
lStage 2 - 9 Nm (7 lbf.ft)
6.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.
7.Remove oil seal guide from crankshaft.
8.Connect multiplug to oil pressure switch.
9.Fill canister of replacement oil filter with clean
engine oil.10.Lubricate oil filter sealing ring with clean engine
oil.
11.Fit oil filter and tighten by hand until it seats
then tighten a further half turn.
12.Lubricate new 'O' rings with clean engine oil
and fit to oil cooler pipe unions.
13.Connect oil cooler pipes to oil filter housing and
tighten unions to 26 Nm (19 lbf.ft).
14.Clean crankshaft gear and wipe end of
crankshaft.
15.Fit crankshaft gear.
16.Fit camshaft timing belt.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
17.Fill engine with oil.

+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.
18.Connect battery earth lead.

ENGINE - K SERIES KV6
REPAIRS 12-3-53
Sump - reseal
$% 12.60.38
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Drain engine oil.

+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.
4.Remove 3 bolts securing RH splash shield to
body and remove shield.
5.Remove 4 nuts securing engine oil cooler to
mounting bracket and position oil cooler aside.6.Remove bolt securing dipstick tube to cylinder
block.
7.Depress and hold down dipstick collar, remove
dipstick tube from sump.
8.Remove 3 bolts securing IRD support bracket
to sump.
9.Using sequence shown and noting their fitted
position, remove 10 bolts securing sump to
lower crankcase.
M12 6614
M12 7916
M12 6672

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
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
REPAIRS 12-3-61
24.Insert LRT-12-161 with LRT-12-199 into
crankshaft pulley, loosen and remove pulley
bolt.
CAUTION: Ensure crankshaft does not
rotate during above operation.
25.Remove tools LRT-12-161 and LRT-12-199
from crankshaft pulley, remove pulley.
26.Remove 3 bolts securing camshaft timing belt
lower cover to cylinder block and remove cover.27.Remove 2 bolts securing ancillary drive belt
tensioner and remove tensioner.
28.Note fitted position of heat shield on A/C
compressor and remove 3 bolts securing A/C
compressor to front mounting plate and
cylinder block. Release A/C compressor and
heat shield and position aside.
29.Remove bolt securing dipstick tube to cylinder
block.
M12 6626
M12 6672

ENGINE - K SERIES KV6
12-3-62 REPAIRS
30.Depress and hold down dipstick tube locking
collar, remove dipstick tube from engine sump.
31.Remove rubber blanking plug from around
camshaft timing belt tensioner.
32.Remove 3 bolts securing engine front mounting
plate and lifting bracket to cylinder block.
33.Remove bolt securing lifting bracket to RH
cylinder head and remove lifting bracket.34.Remove 2 bolts securing IRD support bracket
to engine front mounting plate.
35.Remove 5 bolts and 2 pillar bolts securing
engine front mounting plate to cylinder block.
36.With care, release and remove front mounting
plate from engine.
37.Insert 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
suitable broad bladed screwdriver; this will
move plunger sufficiently to enable pin to be
inserted.

ENGINE - K SERIES KV6
REPAIRS 12-3-63
38.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.
39.If camshaft timing belt is to be refitted, mark
direction of rotation on timing belt before
removal.
40.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 and
cylinder heads fitted.
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.41.Remove and discard LH and RH exhaust
camshaft cap seals.
42.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.
43.Remove and discard bolts retaining front inlet
camshaft gears to camshafts.
44.Remove tools LRT-12-196 from both inlet
camshaft gears and exhaust camshafts.
45.Remove camshaft drive gears and hub
assemblies.

ENGINE - K SERIES KV6
12-3-64 REPAIRS
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 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.Fit hubs to camshaft gears and fit gears to
camshafts. Fit new bolts and tighten sufficiently
to allow gears to rotate without tipping.
3.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.
4.Fit tool LRT-12-197 into each exhaust
camshaft in turn.5.Using assistance, rotate each exhaust
camshaft slightly and align timing marks on LH
and RH rear camshaft gears.
6.Remove tool LRT-12-197 from exhaust
camshaft.
7.Fit tools LRT-12-175 to LH and RH rear
camshaft gears.
8.Rotate both front inlet camshaft gears fully
clockwise as viewed from front of engine.
9.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.
10.Position an Allen key in tensioner backplate
and hold tensioner pulley against timing belt.