2001 LAND ROVER FREELANDER engine

ENGINE - K SERIES KV6
12-3-36 REPAIRS
17.Rotate heated front screen relay anti-clockwise
and release it from 'E' box bracket.
18.Release 4 clips and remove carrier from 'E' box.
19.Remove nut, release retainer and remove 'E'
box.20.Remove engine compartment fuse box cover.
21.Remove 2 bolts securing battery and starter
lead to fuse box.
22.Disconnect multiplug from fuse box.
23.Disconnect earth header multiplug.
24.Release 3 clips securing engine harness to 'E'
box mounting bracket, lay harness over engine.
M12 6765
M12 6766

ENGINE - K SERIES KV6
REPAIRS 12-3-37
25.Remove bolt securing engine earth lead.
26.Disconnect Lucar from starter solenoid.
27.Release 2 gearbox harness multiplugs from
mounting bracket clips and disconnect
multiplugs.28.Position absorbent cloth around fuel feed pipe
connection to collect spillage.
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
29.Pull back rubber sleeve on fuel pipe connector,
release connector and disconnect fuel pipe
from fuel rail pipe.
CAUTION: Always fit plugs to open
connections to prevent contamination.
30.Release purge hose from clip.
31.Release and disconnect hose from purge
control valve.
CAUTION: Always fit plugs to open
connections to prevent contamination.
M12 8005

ENGINE - K SERIES KV6
12-3-38 REPAIRS
32.Release clips and disconnect heater feed and
return hoses from matrix.
33.Release top hose from support bracket, release
clip and disconnect top hose from radiator.34.Release clip and disconnect expansion tank
hose from inlet manifold.
35.Release clip and disconnect hose from
underside of expansion tank.
36.Depress locking collar and disconnect brake
servo hose from inlet manifold chamber.
CAUTION: Always fit plugs to open
connections to prevent contamination.
M12 6774

ENGINE - K SERIES KV6
REPAIRS 12-3-39
37.Raise vehicle on lift.
38.Remove front road wheels.
39.Release stake in drive shaft nuts.
40.With assistant depressing the brake pedal,
remove and discard LH and RH drive shaft
nuts.
41.Remove rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
42.Remove exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - NAS.
43.Raise one rear wheel for rotation of propeller
shaft to access bolts.
44.Reference mark position of viscous coupling
flange to IRD unit flange to aid reassembly.
45.Remove 6 nuts and bolts securing propeller
shaft to IRD drive flange.
46.Release propeller shaft from IRD drive flange
and tie shaft aside.
CAUTION: Care must be taken to support
the Tripode joint when removed from the
IRD unit. To avoid damage to gaiter or steel
can, the joint should not be allowed to fully
extend or be dropped.47.Drain gearbox fluid.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
48.Drain fluid from IRD.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
49.Remove 6 bolts securing RH and LH front
splash shields and remove shields.
50.Remove clips securing brake hoses to RH and
LH damper brackets.
51.Release ABS sensor leads from bracket.
52.Release ABS sensors from RH and LH front
hubs.
M12 6614

ENGINE - K SERIES KV6
12-3-40 REPAIRS
53.Remove nuts securing RH and LH track rod
end ball joints.
54.Fit an M12 nut to each ball pin, flush with end of
each pin.
55.Using 57-043, separate ball pins from RH and
LH steering arms. Remove M12 nuts and
release ball pins from steering arms.
56.Pull RH and LH hubs outwards and release
drive shafts from hubs.57.Using 54-026, release drive shafts from IRD
unit and gearbox.
58.Remove nut securing selector lever to selector
shaft on gearbox and release lever from
selector shaft.
59.Release clip securing selector cable to gearbox
bracket, remove cable and tie aside.

ENGINE - K SERIES KV6
REPAIRS 12-3-41
60.Using a 3/8 square drive socket bar, raise
ancillary drive belt tensioner and release drive
belt from A/C compressor pulley.
61.Disconnect multiplug from A/C compressor.
62.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.
63.Lower vehicle on lift.64.Using a hoist, connect adjustable lifting
bracket, LRT-12-138 to engine.
65.Raise hoist to take weight without exerting any
load on the engine mountings.
66.Remove through bolt securing LH engine
mounting to gearbox bracket.
67.Remove 4 bolts securing LH mounting to body
and remove mounting.
68.Remove 4 bolts securing LH mounting bracket
to gearbox and remove bracket.
M12 6789
M12 6788

ENGINE - K SERIES KV6
12-3-42 REPAIRS
69.Using gearbox bracket bolts, secure LRT-44-
026 lifting bracket to gearbox.
70.Place a wooden block on jack, position jack
under gearbox and raise jack sufficient to
support weight of gearbox. Release lifting hook
from rear engine lifting bracket and connect to
lifting bracket on gearbox.
71.Remove bolt securing upper RH engine steady
to top arm.
72.Loosen bolt securing upper RH engine steady
to body, pivot engine steady away from top
arm.73.Remove bolt securing PAS pipe to engine front
mounting plate.
74.Remove nut and 4 bolts securing engine top
arm bracket to RH hydramount and to engine
front mounting bracket.
75.Release PAS pipe support bracket from
hydramount and position pipe aside.
76.Remove bolt securing PAS pipe to engine front
mounting plate.
77.Remove top arm.
M12 6605

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).