2001 LAND ROVER FREELANDER Workshop Manual

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).

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
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
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
REPAIRS 12-3-47
Hydramount - engine - RH
$% 12.45.12
Remove
1.Remove top arm.

+ ENGINE - K SERIES KV6, REPAIRS,
Arm assembly - engine mounting RH.
2.Position 3 pegs on LRT-12-169 into 3 slots in
hydramount.
3.Connect a suitable socket bar to LRT-12-169,
loosen and remove hydramount and LRT-12-
169.
Refit
1.Clean hydramount and body mating faces.
2.Position hydramount to body.
3.Position 3 pegs on LRT-12-169 into 3 slots in
hydramount.
4.Tighten hydramount to 85 Nm (63 lbf.ft).
5.Fit top arm.

+ ENGINE - K SERIES KV6, REPAIRS,
Arm assembly - engine mounting RH.
Engine steady - upper RH
$% 12.45.16
Remove
1.Remove 2 bolts securing RH engine steady to
top arm and body.
2.Remove engine steady from mounting
brackets.
Refit
1.Position engine steady bar, fit bolts and tighten
to 100 Nm (74 lbf.ft).