2001 LAND ROVER FREELANDER charging

MAINTENANCE
MAINTENANCE 10-21
Clutch Pipes and Unions
Check
1.Check route of clutch pipe from master cylinder
to slave cylinder. Ensure that pipe is correctly
retained and shows no signs of fluid leakage or
chafing.
2. Check unions for signs of fluid leakage.
Windscreen and Rear Washer Reservoir
Check and Top-up
1.Release cap from washer reservoir and fill with
the correct concentration of screen washer
fluid.
2.Refit cap ensuring it is securely fastened.
Battery
Check
1.Check battery condition indicator. Green =
OK. Black = Battery requires charging. Clear/
white = New battery required.
2.Clean and check security of battery terminals.
Smear with petroleum jelly.

ENGINE - K SERIES KV6
REPAIRS 12-3-25
Cover - engine acoustic
$% 12.30.50
Remove
1.Loosen clip and disconnect fresh air intake
hose from acoustic cover.
2. Non NAS: Loosen clip and release air intake
and air bypass hose from throttle body.
3. NAS:Loosen clip and disconnect air intake
hose from air flow meter (MAF) sensor.
4.Release 2 turnbuckles securing acoustic cover
to LH camshaft cover.
5.Release retaining strap and remove acoustic
cover.
Refit
1.Fit and secure engine acoustic cover.
2.Connect air intake and air bypass hoses,
secure clip.
3.Connect fresh air intake hose to acoustic cover
and tighten clip screw.
Engine and automatic gearbox - up to
03MY
$% 12.37.01.99
Remove
1.Disconnect battery earth lead.
2.Tie bonnet back in upright position.
3.Drain cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
4.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
5.Remove battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
6.Remove engine ECM.

+ ENGINE MANAGEMENT SYSTEM -
SIEMENS, REPAIRS, Engine control module
(ECM) - Non NAS.
7.Remove 2 screws securing harness clamp and
remove clamp.
8.Disconnect 2 engine harness to main harness
multiplugs.

ENGINE - K SERIES KV6
12-3-34 REPAIRS
38.With assistant depressing the brake pedal,
tighten front hub nuts to 400 Nm (295 lbf.ft).
39.Stake nut to shaft.
40.Fit front road wheels, fit and tighten nuts to 115
Nm (85 lbf.ft).
41.Lower vehicle on ramp.
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, if fitted.
48.Secure throttle cable in clips on harness
brackets, if fitted.
49.Adjust throttle cable, if fitted.

+ FUEL DELIVERY SYSTEM -
PETROL, ADJUSTMENTS, Throttle cable -
check and adjust - KV6.
50.Connect hose to purge control valve.
51.Connect fuel hose to fuel rail pipe, fit rubber
sleeve over hose connector.
52.Connect gearbox harness multiplugs and
secure multiplugs in mounting bracket clips.
53.Connect Lucar connector to starter solenoid.
54.Position earth lead to gearbox housing, fit and
tighten bolt to 25 Nm (18 lbf.ft).
55.Position engine harness to 'E' box mounting
bracket and secure with clips.
56.Connect earth header multiplug.
57.Connect multiplug to underbonnet fuse box.
58.Position battery and starter motor lead to
underbonnet fuse box, fit and tighten bolts to 8
Nm (6 lbf.ft).
59.Fit underbonnet fuse box cover.
60.Position 'E' box, secure in retaining clip, fit and
tighten nut to 9 Nm (7 lbf.ft).
61.Position carrier in 'E' box and secure with clips.
62.Position and secure air duct and harness
rubber sleeve in 'E' box.
63.Connect multiplugs securing main harness to
engine harness.
64.Position ECM harness and multiplug to 'E' box,
align harness clamp and secure screws to 'E'
box.
65.Fit engine ECM.

+ ENGINE MANAGEMENT SYSTEM -
SIEMENS, REPAIRS, Engine control module
(ECM) - Non NAS.
66.Fit battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.67.Fill cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
68.Connect battery earth lead.
69.Fill gearbox with fluid.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
70.Fit engine acoustic cover.

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

ENGINE - K SERIES KV6
REPAIRS 12-3-35
Engine and automatic gearbox - from
03MY
$% 12.37.01.99
Remove
1.Disconnect battery earth lead.
2.Tie bonnet back in upright position.
3.Drain cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
4.Remove the engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
5.Remove battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
6.Remove engine ECM.

+ ENGINE MANAGEMENT SYSTEM -
SIEMENS, REPAIRS, Engine control module
(ECM) - fuel - NAS.
7.Remove bolt securing heated front screen
harness to battery positive cable.
8.Remove 2 screws securing harness clamp and
remove clamp.
9.Release multiplug from 'E' box and disconnect
body harness from engine harness.
10.Move engine harness aside.11.Disconnect multiplug from 'E' box temperature
sensor.
12.Disconnect multiplug from automatic gearbox
ECU.
13.Disconnect 'E' box cooling fan multiplug.
14.Release body harness clip from 'E' box.
15.Move body harness aside.
16.Release air duct from 'E' box.
M00 0000M12 8001

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.

ENGINE - K SERIES KV6
12-3-46 REPAIRS
Engine mounting - LH
$% 12.45.11
Remove
1.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
2.Remove battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
3.Using a hoist, connect adjustable lifting
bracket, LRT-12-138 to engine.
4.Raise hoist to take weight without exerting any
load on the engine mountings.
5.Remove through bolt securing LH engine
mounting to gearbox bracket.
6.Remove 4 bolts securing LH mounting to body
and remove mounting.Refit
1.Position LH mounting to body, fit and tighten
bolts to 48 Nm (35 lbf.ft).
2.Align gearbox bracket to LH body mounting, fit
and tighten through bolt to 100 Nm (74 lbf.ft).
3.Lower hoist, disconnect and remove lifting
bracket, LRT-12-138.
4.Fit battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
5.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
M12 6599

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
12-3-66 REPAIRS
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.Position PAS pump to front mounting plate, fit
and tighten bolts to 25 Nm (18 lbf.ft).
44.Position PAS pipe to engine front mounting
plate, fit and tighten bolt to 25 Nm (18 lbf.ft).
45.Clean PAS pump pulley mating faces.
46.Position PAS pump pulley, fit and tighten Torx
screws to 9 Nm (7 lbf.ft).
47.Position lower engine steady to sump
mounting, fit and tighten bolt to 100 Nm (74
lbf.ft).
48.Tighten bolt securing lower engine steady to
subframe to 100 Nm (74 lbf.ft).
49.Clean LH rear timing belt cover.
50.Position LH rear timing belt cover, fit and
tighten bolts to 4 Nm (3 lbf.ft).
51.Clean RH rear timing belt cover.
52.position RH rear timing belt cover, fit bolts and
tighten to 4 Nm (3 lbf.ft).
53.Position heat shield, fit bolts and tighten M6 bolt
to 9 Nm (7 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).
54.Fit 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.
55.Fit RH road wheel and tighten nuts to 115 Nm
(85 lbf.ft).
56.Fit ancillary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - KV6.
Camshaft timing belt cover - RH front
$% 12.65.39
Remove
1.Disconnect battery earth lead.
2.Remove ancillary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - KV6.
3.Remove 3 bolts securing camshaft timing belt
RH front cover and remove cover.
Refit
1.Clean RH front timing belt cover.
2.Position RH front timing belt cover, fit and
tighten bolts to 4 Nm (3 lbf.ft).
3.Fit ancillary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - KV6.
4.Connect battery earth lead.