remove seats LAND ROVER FREELANDER 2001 Workshop Manual

GENERAL INFORMATION
03-21
It should be noted that these precautions are not
restricted to operations performed when servicing
the SRS system, the same care should be exercised
when working on ancillary systems and components
located in the vicinity of SRS components; these
include but are not limited to:
lSteering system – steering wheel airbag,
rotary coupler.
lFront fascia – passenger front airbag (where
fitted); SRS DCU behind centre console, on
transmission tunnel under the HeVAC system.
lFront seats – seat belt pre-tensioners, integral
with seat belt buckle assembly.
lElectrical system – SRS harnesses, link leads
and connectors.
Making the SRS system safe
Before working on or in the vicinity of SRS
components, ensure the system is rendered safe by
performing the following procedures:
lRemove the ignition key from the ignition switch.
lDisconnect both battery leads, earth lead first.
lWait 10 minutes for the SRS DCU back-up
power circuit to discharge.
The SRS system uses energy reserve capacitors
that keep the system active in the event of electrical
supply failure under crash conditions. It is necessary
to allow the capacitor sufficient time to discharge (10
minutes) in order to avoid the risk of accidental
deployment.
WARNING: Always disconnect both battery leads
before beginning work on the SRS system.
Disconnect the negative battery lead first. Never
reverse connect the battery.Installation
In order to assure system integrity, it is essential that
the SRS system is regularly checked and maintained
so that it is ready for effective operation in the event
of a collision. Carefully inspect SRS components
before installation. Do not install a part that shows
signs of being dropped or improperly handled, such
as dents, cracks or deformation.
WARNING: The integrity of SRS system
components is critical for safety reasons. Ensure
the following precautions are always adhered to:
lNever install used SRS components from
another vehicle or attempt to repair an SRS
component.
lWhen repairing an SRS system only use
genuine new parts.
lNever apply electrical power to an SRS
component unless instructed to do so as
part of an approved test procedure.
lSpecial Torx bolts are necessary for
installing the airbag module — do not use
other bolts. Ensure bolts are tightened to the
correct torque.
lAlways use new fixings when replacing an
SRS component.
lEnsure the SRS Diagnostic Control Unit
(DCU) is always installed correctly. There
must not be any gap between the DCU and
the bracket to which it is mounted. An
incorrectly mounted DCU could cause the
system to malfunction.
CAUTION: Ensure SRS components are not
contaminated with oil, grease, detergent or
water.
Ensure that SRS component fixings are correctly
positioned and torqued during service and repair.
CAUTION: Torque wrenches should be regularly
checked for accuracy to ensure that all fixings
are tightened to the correct torque.
If you suspect an airbag assembly could be
defective, install a new unit and dispose of the old
unit. Manually deploy the old unit before disposal.

MAINTENANCE
MAINTENANCE 10-23
Engine Oil and Filter – K1.8
Drain
1.Raise vehicle on ramp.
2.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Place a suitable container under engine sump
drain plug, remove plug and discard sealing
washer. Allow oil to drain.
WARNING: Observe due care when draining
engine oil as the oil can be very hot.
WARNING: Avoid excessive skin contact
with used engine oil. Used engine oil
contains potentially harmful contaminants
which may cause skin cancer or other
serious skin disorders.
4.Remove and discard engine oil filter.Refill
1.Lubricate sealing ring of new filter with clean
engine oil.
2.Fit new filter and tighten by hand until it seats,
then tighten a further half a turn.
3.Clean sump drain plug and fit new sealing
washer.
4.Fit sump drain plug and tighten to 25 Nm (18
lbf.ft).
5.Remove engine oil filler cap and fill engine with
oil to correct level.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
6.Fit oil filler cap.
7.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
8.Lower vehicle.
9.Start engine. Run at idle until oil pressure
warning light extinguishes.
10.Stop engine. Recheck engine oil level.
11.Check for signs of leakage.

MAINTENANCE
10-24 MAINTENANCE
Engine Oil and Filter – KV6
Drain
1.Raise vehicle on ramp.
2.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Place a suitable container under engine sump
drain plug, remove plug and discard sealing
washer. Allow oil to drain.
WARNING: Observe due care when draining
engine oil as the oil can be very hot.
WARNING: Avoid excessive skin contact
with used engine oil. Used engine oil
contains potentially harmful contaminants
which may cause skin cancer or other
serious skin disorders.
4.Remove and discard engine oil filter.

+ ENGINE - K SERIES KV6, REPAIRS,
Filter - engine oil.Refill
1.Fill canister of replacement oil filter with clean
engine oil.
2.Lubricate sealing ring of new filter with clean
engine oil.
3.Fit new filter and tighten by hand until it seats,
then tighten a further half turn.
4.Clean sump drain plug and fit new sealing
washer.
5.Fit sump drain plug and tighten to 25 Nm (18
lbf.ft).
6.Remove engine oil filler cap and fill engine with
oil to correct level.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
7.Fit oil filler cap.
8.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
9.Lower vehicle.
10.Start engine. Run at 2500 rev/min until oil
pressure warning light extinguishes.
11.Stop engine. Recheck engine oil level.
12.Check for signs of leakage.

ENGINE - K SERIES KV6
REPAIRS 12-3-33
71.Remove 3 bolts securing PAS pump to front
mounting plate and tie pump aside.
72.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 (18 lbf.ft).
3.Position PAS pump pulley, fit and tighten Torx
screws to 9 Nm (7 lbf.ft).
4.Position top arm to engine mounting bracket
and RH hydramount, fit and tighten bolts to 100
Nm (74 lbf.ft).
5.Position PAS pipe support bracket to RH
hydramount, fit and tighten nut to 85 Nm (63
lbf.ft).
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 LRT-44-026 lifting
bracket to gearbox and remove bracket.
9.Position LH mounting bracket to gearbox, fit
and tighten bolts to 85 Nm (63 lbf.ft).
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 (74 lbf.ft).
12.Position upper RH engine steady to top arm, fit
and tighten bolt to 100 Nm (74 lbf.ft).
13.Tighten bolt securing upper RH engine steady
to body to 100 Nm (74 lbf.ft).
14.Position PAS pipe to engine front mounting
plate, fit and tighten bolt to 25 Nm (18 lbf.ft).
15.Lower hoist, disconnect and remove lifting
bracket, LRT-12-138.
16.Raise vehicle on ramp.17.Position A/C compressor to front mounting
plate and cylinder block, align heat shield, fit
and tighten bolts to 25 Nm (18 lbf.ft).
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 (18 lbf.ft).
22.Clean splines and seal areas on each
driveshaft and mating faces in front hubs.
23.Fit new circlips to RH and LH driveshaft inner
joint splines.
24.Fit driveshafts to IRD and gearbox, ensuring
that the circlip on each driveshaft is fully
engaged.
25.Engage LH and RH driveshafts into front hubs.
26.Fit new driveshaft 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 (40
lbf.ft).
29.Clean ABS sensors and mating faces.
30.Apply anti-seize grease to both ABS sensors
and position sensors in front hubs.
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).
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) fluid - drain & refill -
Non NAS.

+ 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 - Non
NAS.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - NAS.

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
12-3-50 REPAIRS
Filter - engine oil
$% 12.60.04
Remove
1.Raise vehicle on a 4 post ramp.
2.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Place suitable container under oil filter to collect
spillage.
4.Using strap wrench, remove and discard oil
filter.
WARNING: Avoid excessive skin contact
with used engine oil. Used engine oil
contains potentially harmful contaminants
which may cause skin cancer or other
serious skin disorders.
Refit
1.Clean oil filter mating face.
2.Fill canister of replacement oil filter with clean
engine oil.
3.Lubricate new oil filter sealing ring with clean
engine oil.
4.Fit new oil filter and tighten by hand until it
seats, then tighten a further half turn.
5.Remove oil container from underneath of
engine.
6.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
7.Lower vehicle on ramp.
8.Start and run engine and check for leaks.
9.Stop engine, wait a few minutes, then check oil
level. Top up if necessary.

+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.
Oil pick-up strainer
$% 12.60.20
Remove
1.Disconnect battery earth lead.
2.Remove engine sump.

+ ENGINE - K SERIES KV6, REPAIRS,
Sump - reseal.
3.Remove bolt and remove oil pick-up strainer.
Remove and discard 'O' ring.
Refit
1.Clean oil pick-up strainer and mating face.
2.Remove all traces of sealant from oil strainer
bolt hole and bolt threads.
CAUTION: Do not use a tap.
3.Lubricate new 'O' ring with clean engine oil and
fit to pick-up strainer.
CAUTION: Ensure 'O' ring, Part No.
LYX000210L is fitted.
4.Apply sealant, Part No. STC 50552 to threads
of oil pick-up strainer retaining bolt.
5.Position oil pick-up strainer, fit and tighten bolt
to 8 Nm (6 lbf.ft).
6.Fit engine sump.

+ ENGINE - K SERIES KV6, REPAIRS,
Sump - reseal.
7.Connect battery earth lead.
M12 6660

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
OVERHAUL 12-3-79
9.Ensure rings are free to rotate, position
compression ring gaps A and B at 120° to each
other and away from thrust side. Position oil
control ring gap C and spring gap D at 30° on
opposite side of gudgeon pin axis.
10.Check clearance of each piston ring to its
respective groove.

+ GENERAL DATA, Engine - KV6
Petrol.Reassembly
1.Clean cylinder liners and liner recess in cylinder
block.
2.Lubricate cylinder liner bores, pistons and rings
with clean engine oil, ensure ring gaps are
correctly spaced.
3.Clean bearing shell recesses in connecting
rods and bearing caps.
4.Fit piston ring clamp, LRT-12-204 to each
piston in turn and fit piston to its respective
cylinder liner ensuring that when fitted, arrow
on piston crown will be towards front of engine.
CAUTION: Do not push pistons fully down
bores at this stage.
5.Remove piston ring clamp.
6.Apply a 2.00 mm (0.1 in) thick continuous bead
of sealant, Part No. RTC 3347, around
shoulder of each cylinder liner as shown.
7.Keeping cylinder liner 'square' to cylinder block,
push each liner fully down until shoulder of liner
seats against cylinder block ensuring that the
arrow on the piston is towards front of engine.
8.To prevent cylinder liners from being displaced,
position LRT-12-144 cylinder liner clamps and
secure to cylinder block with cylinder head
bolts. Ensure that feet of clamps do not
protrude over liner bores.
9.Fit crankshaft.

+ ENGINE - K SERIES KV6,
OVERHAUL, Crankshaft.
M12 6839
D
BA
C
M12 6842

ENGINE - K SERIES KV6
12-3-100 OVERHAUL
31.Check that fitted height of valve guide, 'A', is
6.00 mm (0.24 in).
32.Check condition of valve seats and existing
valves that are to be re-used.
33.Renew valve seat inserts as necessary.
CAUTION: Do not damage counterbore
when removing insert.
34.Cool replacement valve seat inserts using
liquid nitrogen and press into cylinder head in
one continuous operation.
CAUTION: Do not heat cylinder head.
Inserts must not stand proud of combustion
face on completion of cutting operation.
35.Cut valve seats using a suitable pilot and the
following cutters:
l15° - To cut first angle
l45° - Make final cut and remove any burrs
l60° - To narrow seat and obtain correct
valve seat width
36.Check valve seat width and face angle:
lSeat width - 'A' - Inlet = 1.2 mm (0.05 in);
Exhaust = 1.6 mm (0.06 in)
lValve face angle - 'B' - Inlet and exhaust =
45°
37.Lap each valve to its seat using grinding paste.38.Apply Prussian Blue to valve seat, insert valve
and press it into position several times without
rotating. Remove and check valve for even and
central seating: seating position shown by
Prussian Blue should be in the centre of valve
face: a: High towards stem, increase 60° cut
and restore seat width. b: Low towards edge,
increase 45° cut and restore seat width. Lap
and recheck valve seating.
39.Check valve stem fitted height - 'A'.

+ GENERAL DATA, Engine - KV6
Petrol.
CAUTION: If valve stem fitted height is
above service limit, fit new valve and re-
check. If still over limit, renew valve seat
insert.
40.Clean valve springs and lubricate valves.
Reassembly
1.Lubricate new valve stem oil seals with clean
engine oil.
2.Using tool LRT-12-071 fit new valve stem oil
seals.
3.Fit valves.
M12 7894
A

RESTRAINT SYSTEMS
REPAIRS 75-1
RESTRAINT SYSTEMS REPAIRS
Automatic belt assembly - front - 3 door
$% 76.73.13
Remove
1.Remove seat base finisher.

+ SEATS, REPAIRS, Finisher - seat
base - front - each.
2.Remove body side rear trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - body side - rear - 3
door.
3.Remove 2 Torx bolts securing seat belt lower
mounting and remove mounting from seat belt.
4.Release seat belt retaining strap.
5.Remove cover from upper mounting.
6.Remove Torx bolt from upper mounting.
7.Remove bolt from seat belt reel and remove
reel.Refit
NOTE: If the SRS component is to be replaced,
the bar code of the new unit must be recorded.
1.Position reel and tighten bolt to 31 Nm (23
lbf.ft).
2.Extend belt, position top mounting and tighten
Torx bolt to 31 Nm (23 lbf.ft).
3.Fit top mounting cover.
4.Secure belt retaining strap.
5.Fit lower mounting to seat belt, position
mounting, fit and tighten Torx bolts to 40 Nm
(29 lbf.ft).
6.Fit body rear side trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - body side - rear - 3
door.
7.Fit seat base finisher.

+ SEATS, REPAIRS, Finisher - seat
base - front - each.