2001 LAND ROVER FREELANDER cooling

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
REPAIRS 12-3-57
Oil cooler - engine
$% 12.60.68
Remove
1.Disconnect battery earth lead.
2.Drain cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
3.Remove RH front road wheel.
4.Remove 3 bolts securing RH splash shield to
body and remove shield.
5.Position container to collect spillage under oil
filter.
6.Loosen and remove oil cooler pipe unions from
oil filter housing, remove and discard 2 'O'
rings.
CAUTION: Failure to retain bosses will
result in damage to oil cooler. Always fit
plugs to open connections to prevent
contamination.
7.Position container to collect coolant spillage.8.Release clips and disconnect coolant hoses
from engine oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
9.Remove 4 nuts securing engine oil cooler to
mounting bracket and remove oil cooler.
10.Restrain oil cooler pipe bosses on oil cooler
housing, loosen and remove oil cooler pipes
from oil cooler; remove and discard 2 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
Refit
1.Clean oil cooler pipe unions and mating faces.
2.Lubricate new 'O' rings with clean engine oil
and fit to oil cooler pipes.
3.Fit pipes to engine oil cooler, restrain bosses on
oil cooler body and tighten unions to 26 Nm (19
lbf.ft).
CAUTION: To prevent damage to
components, use two spanners when
loosening or tightening unions.
4.Position engine oil cooler to mounting bracket,
fit and tighten nuts to 25 Nm (18 lbf.ft).
5.Position oil cooler pipes to oil filter housing and
tighten unions to 26 Nm.
6.Connect coolant hoses to oil cooler and secure
with clips.
7.Fit splash shield and secure with bolts.
8.Fit RH road wheel and tighten nuts to 115 Nm
(85 lbf.ft).
9.Fill cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
10.Connect battery earth lead.
11.Check engine oil level and top-up if necessary.
M12 6614
M12 7917

EMISSION CONTROL
REPAIRS 17-1-9
Thermal valve - exhaust gas
recirculation (EGR) - Td4 Automatic
transmission (hot climates) - from 03 MY
$% 17.45.07
Remove
1.Disconnect the battery earth lead.
2.Release thermal valve coolant hose from clips.
3.Position container to collect coolant.
4.Release 3 clips securing coolant hoses to the
EGR thermal valve.
5.Disconnect coolant hoses from the EGR
thermal valve and remove the thermal valve.
Refit
1.Position the EGR thermal valve and connect
coolant hoses.
2.Secure hoses with clips.
3.Fit thermal valve coolant hose into clips.
4.Connect the battery earth lead.
5.Refill the cooling system.

+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.
Cooler - EGR - Td4
$% 17.45.40
Remove
1.Disconnect battery earth lead.
2.Remove camshaft cover.

+ ENGINE - Td4, REPAIRS, Gasket -
camshaft cover.
3.Mark EGR pipe and cooler to aid refit.
4.Loosen clamps EGR pipes to cooler and move
clamps aside.
5.Remove pipe, EGR cooler to EGR valve.
6.Remove bolt securing fuel rails to support
bracket.
7.Remove bolt securing turbocharger outlet pipe
to support bracket.
8.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
M170364

M17 0283

EMISSION CONTROL
17-1-10 REPAIRS
9.Remove bolt securing turbo outlet pipe to upper
coolant rail.
10.Remove 2 bolts securing pipe support bracket
to engine lifting bracket, remove support
bracket.
11.Release clip and remove vacuum hose.
12.Remove 3 bolts securing EGR cooler to
cylinder head and lifting bracket.13.Lift EGR cooler from mounting and position a
container beneath coolant hoses.
14.Release clips and remove hoses from EGR
cooler allow coolant to drain.
15.Remove EGR cooler.
Refit
1.Position EGR cooler, connect coolant hoses
and fit clips.
2.Position EGR cooler to mounting, fit bolts and
tighten to 25 Nm (18 lbf.ft).
3.Position pipe support bracket to engine lifting
bracket, fit and tighten bolts to 25 Nm (18 lbf.ft).
4.Fit vacuum hose and tighten clip.
5.Fit bolt securing turbocharger pipe to coolant
rail and tighten to 25 Nm (18 lbf.ft).
6.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
7.Fit bolt securing turbocharger outlet pipe to
support bracket and tighten to 10 Nm (7.5
lbf.ft).
8.Fit bolt securing fuel rails to support bracket
and tighten to 10 Nm (7.5 lbf.ft).
9.Align EGR pipe to cooler fit clamp, but do not
fully tighten until camshaft cover is refitted.
10.Fit EGR pipe clamp and tighten screw.
11.Fit camshaft cover.

+ ENGINE - Td4, REPAIRS, Gasket -
camshaft cover.
12.Connect battery earth lead.
13.Top up cooling system.

+ MAINTENANCE, MAINTENANCE,
Cooling System and Intercooler.

ENGINE MANAGEMENT SYSTEM - SIEMENS
18-3-8 REPAIRS
Sensor - intake air temperature (IAT) -
NAS
$% 18.30.09
Remove
1.Disconnect multiplug from IAT sensor.
2.Release clip and remove IAT sensor. Discard
seal.
Refit
1.Clean IAT sensor and mating face.
2.Fit new seal to sensor.
3.Fit IAT sensor and connect multiplug.
Sensor - engine coolant temperature
(ECT)
$% 18.30.10
Remove
1.Disconnect battery earth lead.
2.Remove thermostat.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Thermostat.
3.Disconnect multiplug from coolant temperature
sensor.
4.Remove coolant temperature sensor and
discard sealing washer.
5.Remove coolant temperature sensor from
cylinder block.
6.Remove steel shim and sealing washer from
temperature sensor, discard sealing washer.
Refit
1.Clean coolant temperature sensor and mating
face on cylinder block.
2.Fit new sealing washer, then steel shim to
coolant temperature sensor.
3.Position coolant temperature sensor and
tighten to 17 Nm (12.5 lbf.ft).
4.Fit thermostat.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Thermostat.
5.Connect battery earth lead.

COOLING SYSTEM - K SERIES KV6
ADJUSTMENTS 26-3-1
COOLING SYS TEM - K SER IES KV6 ADJUST ME NTS
Coolant - drain and refill
$% 26.10.01
Drain
1.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
2.Visually check engine and cooling system for
signs of coolant leaks.
WARNING: Since injury such as scalding
could be caused by escaping steam or
coolant, do not remove the filler cap from
the coolant expansion tank while the
system is hot.
3.Examine hoses for signs of cracking, distortion
and security of connections.
4.Remove expansion tank filler cap.
5.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
6.Position container to collect coolant.
7.Remove cylinder block drain plug.
8.Release clip and remove bottom hose from
radiator.
9.Allow cooling system to drain.Refill
1.Flush system with water under low pressure.
Do not use water under high pressure as it
could damage the radiator.
2.Clean cylinder block drain plug and apply
sealant, Part No. STC 50552 to first 3 threads.
3.Fit cylinder block drain plug and tighten to 20
Nm (15 lbf.ft).
4.Fit bottom hose to radiator and secure with clip.
5.Prepare coolant to required concentration.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Fluids.
6.Remove bleed screw from heater return hose.
7.Slowly fill the system through the coolant
expansion tank until a steady flow of coolant is
emitted from the bleed hole.
8.Fit and close bleed screw in heater return hose.
9.Continue to fill system through the expansion
tank until coolant reaches to the base of the
expansion tank bleed hose.
10.Fit expansion tank filler cap.
11.Start and run engine at idle speed for 5
minutes.
CAUTION: DO NOT operate air conditioning
12.Switch off engine.
13.Squeeze bottom hose several times to remove
any trapped air.
14.Start engine and run at speeds varying
between idle speed and 3500 rev/min for 7
minutes.
15.Switch off engine and allow to cool.
16.Remove expansion tank filler cap and add
coolant until it reaches the 'MAX' mark on the
expansion tank.
17.Fit expansion tank filler cap.
18.Start and run engine until normal operating
temperature is reached.
CAUTION: The bottom hose must be warm/
hot, this will ensure the thermostat is fully
open.