2001 LAND ROVER FREELANDER brake sensor

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 12-3-39
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
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.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-15
17. NAS models: Disconnect injector air supply
pipe from intake hose.
18. NAS models: Disconnect multiplug from
throttle body.
19. NAS models: Release clip and remove intake
hose and MAF sensor assembly.
20.Disconnect cruise control actuator vacuum
pipe.21.Depress locking collar and disconnect brake
servo hose from inlet manifold chamber.
22.Disconnect multiplugs from VIS motors.
23.Remove 2 screws securing engine harness
brackets to inlet manifold chamber and position
harness aside.
M19 3198

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-17
30.Remove and discard seals from inlet manifold
chamber and 'O' rings from RH inlet manifold.Refit
1.Clean seal faces on inlet manifold chamber and
inlet manifolds.
2.Fit new 'O' rings to RH inlet manifold and new
seals to manifold chamber.
3.Position inlet manifold chamber, secure RH coil
harness clips in inlet manifold chamber support
brackets.
4.Connect multiplugs to plug top coils and secure
with locking clips.
5.Align inlet manifold chamber to inlet manifolds,
fit and tighten bolts to 18 Nm (13 lbf.ft).
6.Align inlet manifold chamber support brackets
to RH camshaft cover, fit and tighten bolts to 10
Nm (7.5 lbf.ft).
7.Position engine harness brackets to inlet
manifold chamber, fit and tighten screws.
8.Connect multiplugs to VIS motors.
9. NAS models: Connect engine breather pipe.
10. NAS models: Connect multiplugs to IAT and
MAF sensors.
11.Connect brake servo vacuum hose to inlet
manifold chamber.
12.Connect vacuum/breather hoses to LH and RH
camshaft covers and to throttle body.
13.Connect cruise control actuator vacuum pipe.
14. Non NAS models: Connect vacuum hose to
IACV housing.
15. Non NAS models: Connect multiplugs to TP
and IACV sensors.
16.Connect vacuum/breather hoses to LH
camshaft cover, 'T' piece and purge control
valve.
17. Non NAS models: Connect small vacuum
hose to purge control valve.
18.Connect multiplug to purge control valve .
19.Connect EVAP hose to purge control valve.
20.Connect fuel hose to fuel rail pipe, fit rubber
sleeve over hose connector.
21.Remove absorbent cloth.
22. Non NAS models: Connect throttle inner cable
to throttle cam and secure outer cable in
abutment bracket.
23. Non NAS models: Secure throttle cable in
clips on harness brackets.
24.Adjust throttle cable, if fitted.

+ FUEL DELIVERY SYSTEM -
PETROL, ADJUSTMENTS, Throttle cable -
check and adjust - KV6.
25.Remove vacuum enhancer.

+ BRAKES, REPAIRS, Vacuum -
enhancer - KV6.
26.Connect battery earth lead.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-18 REPAIRS
Seals - inlet manifold chamber - from
03MY
$% 30.15.37
Remove
1.Disconnect battery earth lead.
2.Remove vacuum enhancer.

+ BRAKES, REPAIRS, Vacuum -
enhancer - KV6.
3.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.
4.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.
5.Release and disconnect EVAP hose from
purge control valve.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Disconnect multiplug from purge control valve.7. Non NAS models: Disconnect small vacuum
pipe from purge control valve.
8. Non NAS models: Depress locking collar and
release vacuum pipe from IACV housing.
CAUTION: Always fit plugs to open
connections to prevent contamination.
9. Non NAS models: Disconnect multiplug from
IACV.
10. Non NAS models: Disconnect multiplug from
TP sensor.
11. Non NAS models: Depress locking collars and
release vacuum/breather pipe from purge
control valve and LH camshaft cover. Release
clip securing hose to 'T' piece and remove pipe.
CAUTION: Always fit plugs to open
connections to prevent contamination.
M30 1171

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-22 REPAIRS
Refit
1.Clean seal faces on inlet manifold chamber and
inlet manifolds.
2.Fit new 'O' rings to RH inlet manifold and new
seals to inlet manifold chamber.
3.Position inlet manifold chamber, secure RH coil
harness clips in inlet manifold chamber support
brackets.
4.Align inlet manifold chamber to inlet manifolds,
fit and tighten bolts to 18 Nm (13 lbf.ft).
5.Align inlet manifold chamber support brackets
to RH camshaft cover, fit and tighten bolts to 10
Nm (7 lbf.ft).
6.Connect multiplugs to plug top coils and secure
with locking clips.
7.Position engine harness brackets to inlet
manifold chamber, fit and tighten screws.
8.Connect multiplugs to VIS motors.
9. NAS models: Align harness and fuel feed pipe.
Secure harness and pipe in clip on manifold
chamber.
10. NAS models: Using a new clip, fit intake hose
to throttle body and secure hose with clip.
11. NAS models: Connect multiplug to throttle
body.
12. NAS models: Connect multiplugs to IAT and
MAF sensors.
13. NAS models: Fit vacuum/breather pipe and
connect to LH camshaft cover, RH camshaft
cover link pipe and inlet manifold chamber.
14. NAS models: Using a new clip, fit vacuum/
breather pipe to engine air intake hose and
secure pipe with clip.
15. NAS models: Connect vacuum/breather pipe
to LH and RH camshaft covers. Fit pipe into
clip.16. Non NAS models: Connect cruise control
actuator vacuum pipe.
17. Non NAS models: Fit vacuum/breather pipe to
throttle body and connect pipe to LH and RH
camshaft covers.
18. Non NAS models: Fit vacuum/breather pipe to
purge control valve and LH camshaft cover.
Using a new clip, connect pipe to 'T' piece and
secure pipe with clip.
19. Non NAS models: Connect multiplug to TP
sensor.
20. Non NAS models: Connect multiplug to IACV.
21. Non NAS models: Connect vacuum pipe to
IACV.
22. Non NAS models: Connect small vacuum pipe
to purge control valve.
23.Connect multiplug to purge control valve .
24.Connect EVAP hose to purge control valve.
25.Connect fuel hose to fuel rail pipe, fit rubber
sleeve over hose connector.
26. Non NAS models: Connect throttle inner cable
to throttle cam and secure outer cable in
abutment bracket.
27. Non NAS models: Secure throttle cable in
clips on harness brackets.
28. Non NAS models: Adjust throttle cable.

+ FUEL DELIVERY SYSTEM -
PETROL, ADJUSTMENTS, Throttle cable -
check and adjust - KV6.
29.Fit vacuum enhancer.

+ BRAKES, REPAIRS, Vacuum -
enhancer - KV6.
30.Connect the battery earth lead.