2001 LAND ROVER FREELANDER engine coolant

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

ENGINE - K SERIES KV6
REPAIRS 12-3-63
38.Remove and discard 2 Patchlok bolts securing
tensioner to cylinder block and remove
tensioner.
CAUTION: Exercise great care when
removing bolts, do not apply excessive
torque. If bolts appear to be seized, apply
suitable anti-seize lubricant prior to
removing bolts. DO NOT loosen Allen screw
securing tensioner pulley.
39.If camshaft timing belt is to be refitted, mark
direction of rotation on timing belt before
removal.
40.With care, ease camshaft timing belt from
gears using fingers only and remove timing
belt.
CAUTION: Do not rotate crankshaft or
camshafts with timing belt removed and
cylinder heads fitted.
CAUTION: Camshaft timing belt must be
replaced if cylinder head is to be removed or
new drive gears, tensioner or coolant pump
are to be fitted. Camshaft timing belts must
be stored and handled with care. Always
store a camshaft timing belt on its edge with
a bend radius greater than 50 mm (2.0 in).
Do not use a camshaft timing belt that has
been twisted or bent double as this will
damage the reinforcing fibres. Do not use a
camshaft timing belt if debris other than belt
dust is found in timing belt covers. Do not
use a camshaft timing belt if partial engine
seizure has occurred. Do not use a
camshaft timing belt if mileage exceeds
72,000 km (45,000 miles). Do not use an oil
or coolant contaminated timing belt, cause
of contamination must be rectified.41.Remove and discard LH and RH exhaust
camshaft cap seals.
42.Position tools LRT-12-196 to LH and RH front
inlet camshaft gears and into the end of each
exhaust camshaft.
CAUTION: Special tools must be fitted when
tightening or loosening gear retaining bolts,
otherwise damage to camshafts may occur.
43.Remove and discard bolts retaining front inlet
camshaft gears to camshafts.
44.Remove tools LRT-12-196 from both inlet
camshaft gears and exhaust camshafts.
45.Remove camshaft drive gears and hub
assemblies.

ENGINE - K SERIES KV6
12-3-70 REPAIRS
8.Remove and discard LH front exhaust
camshaft cap seal from cylinder head.
9.Position LRT-12-175 to rear camshaft gears as
illustrated, remove and discard bolts securing
gears to camshafts.
10.Remove rear camshaft gears, timing belt and
special tool as an assembly.
CAUTION: Do not turn the crankshaft or the
camshafts while the timing belt is removed.
11.If camshaft timing belt is to be refitted, mark
direction of rotation on timing belt.12.Remove LRT-12-175 from camshaft gears and
remove timing belt from gears.
CAUTION: Do not rotate crankshaft or
camshafts with timing belt removed and
cylinder heads fitted.
CAUTION: Camshaft timing belts must be
stored and handled with care. Always store
a camshaft timing belt on its edge with a
bend radius greater than 50 mm (2.0 in). Do
not use a camshaft timing belt that has been
twisted or bent double as this will damage
the reinforcing fibres. Do not use a
camshaft timing belt if debris other than belt
dust is found in timing belt covers. Do not
use a camshaft timing belt if partial engine
seizure has occurred. Do not use a
camshaft timing belt if mileage exceeds
72,000 km (45,000 miles). Do not use an oil
or coolant contaminated timing belt, cause
of contamination must be rectified.

ENGINE - K SERIES KV6
12-3-74 REPAIRS
8.Remove and discard RH front exhaust
camshaft cap seal from cylinder head.
9.Position LRT-12-175 to rear camshaft gears as
illustrated, remove and discard bolts securing
gears to camshafts.
10.Remove rear camshaft gears, timing belt and
special tool as an assembly.
CAUTION: Do not turn the crankshaft or the
camshafts while the timing belt is removed.
11.If camshaft timing belt is to be refitted, mark
direction of rotation on timing belt.12.Remove LRT-12-175 from camshaft gears and
remove timing belt from gears.
CAUTION: Camshaft timing belts must be
stored and handled with care. Always store
a camshaft timing belt on its edge with a
bend radius greater than 50 mm (2.0 in). Do
not use a camshaft timing belt that has been
twisted or bent double as this will damage
the reinforcing fibres. Do not use a
camshaft timing belt if debris other than belt
dust is found in timing belt covers. Do not
use a camshaft timing belt if partial engine
seizure has occurred. Do not use a
camshaft timing belt if mileage exceeds
72,000 km (45,000 miles). Do not use an oil
or coolant contaminated timing belt, cause
of contamination must be rectified.

ENGINE - K SERIES KV6
OVERHAUL 12-3-85
9. Big-end bearings selection: Select the
required bearing shells from general data.

+ GENERAL DATA, Engine - KV6
Petrol.
10.Ensure all bolt holes are clean and dry.
Remove all traces of thread locking material
from oil pick-up strainer bolt hole and threads of
retaining bolt.
CAUTION: Do not use a tap.
11.Ensure bearing ladder locating dowels are
fitted and dowel holes in bearing ladder are
clean and dry.
12.Check coolant stub pipe in cylinder block for
signs of leakage and corrosion, replace as
necessary. Apply sealant, Part No. STC 50554
to seal replacement pipe to cylinder block.
13.Clean main bearing shell recesses in cylinder
block.
14.Clean crankshaft main bearing and big end
bearing journals. Clean bearing shell locations
in connecting rods and caps.
15.Fit selected main bearing shells, grooved into
cylinder block and plain into bearing ladder.
16.Fit new thrust washers to cylinder block.
17.Position DTI gauge stylus on end of crankshaft
as illustrated, push crankshaft away from DTI,
zero DTI gauge, push crankshaft in the
opposite direction and note reading on gauge.

+ GENERAL DATA, Engine - KV6
Petrol.
CAUTION: If end-float exceeds limits given,
crankshaft must be replaced.Reassembly
1.Fit selected big-end bearing shells to
connecting rods and caps.
2.Lubricate crankshaft journals with clean engine
oil. Hold crankshaft with big end journals
horizontal, lower crankshaft into main bearings.
3.Carefully pull connecting rods into place, fit
connecting rod caps noting that featherways
are on opposite sides; fit and lightly tighten
dowel bolts.
4.Tighten dowel bolts to:
lStage 1 - 20 Nm (15 lbf.ft)
lStage 2 - Further 45°
5.Using a lint free cloth and a suitable cleaning
solvent, clean bearing ladder and mating face
on cylinder block.
6.Apply clean engine oil to crankshaft thrust
washers and fit to bearing ladder with oil
grooves facing outwards.
7.Fit bearing ladder and ensure that all bearing
shells are seated correctly.
8.Noting that longest bolts must be fitted in inner
holes in bearing ladder, fit new bolts and tighten
to:
lStage 1 - 20 Nm (15 lbf.ft)
lStage 2 - Further 90°
9.Using a lint free cloth and a suitable cleaning
solvent, clean mating surfaces on cylinder
block and lower crankcase.

ENGINE - K SERIES KV6
12-3-88 OVERHAUL
7.Release clip and disconnect coolant bleed
hose from LH inlet manifold, position hose
aside.
8.Depress locking collar and release breather
hose from LH inlet manifold.
9.Release clips securing RH injector harness to
injector protection cover - if fitted, or from
bosses on fuel rail.10.Remove 2 bolts securing protection cover - if
fitted and RH fuel rail to RH inlet manifold,
remove cover.
11.Remove 2 bolts securing fuel rail to LH inlet
manifold.
12.Release injectors from manifolds and carefully
lay fuel rail and injectors aside.
CAUTION: Always fit plugs to open
connections to prevent contamination.

ENGINE - K SERIES KV6
12-3-90 OVERHAUL
10.Tighten cylinder head bolts progressively in the
sequence shown to:
lStage 1 - 25 Nm (18 lbf.ft)
lStage 2 - 25 Nm (18 lbf.ft)
lStage 3 - 25 Nm (18 lbf.ft)
lStage 4 - Using an angle torque gauge,
tighten a bolts in same sequence a further
180°
11.Fit LH camshaft cover gasket.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - LH - Up to 03MY.
12.Remove and discard 'O' rings from injectors.
13.Clean injectors and injector locations in fuel rail.
14.Lubricate new 'O' rings with castor oil and fit to
injectors.
15.Position fuel rail assembly and secure injectors
to inlet manifolds.
16.Position injector protection cover - if fitted to RH
fuel rail and secure injector harness to
protection cover or fuel rail with clips.
17.Fit bolts securing fuel rail to inlet manifolds and
tighten to 9 Nm (7 lbf.ft).
18.Connect coolant bleed hose to inlet manifold
and secure with clip.
19.Connect breather hose to LH inlet manifold.
20.Position ignition coils to LH inlet manifold.
21.Position earth lead, fit nuts and bolts securing
ignition coils to LH inlet manifold and tighten to
9 Nm (7 lbf.ft).
22.Clean camshaft drive belt cover backplate bolts
and apply sealant, Part No. STC 50552 to first
3 threads.
23.Position backplate, fit and tighten bolts to 9 Nm
(7 lbf.ft).
24.Clean exhaust manifold and cylinder head
mating face.25.Fit new exhaust manifold gasket. Position
exhaust manifold, fit nuts and using sequence
shown, tighten to 45 Nm (33 lbf.ft).
26.Secure HO2S lead in clip on cylinder block.
27.Connect HO2S multiplug and secure to support
bracket.
28.Fit new camshaft timing belt.

+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.