2001 LAND ROVER FREELANDER height

ENGINE - K SERIES KV6
12-3-78 OVERHAUL
2.Cylinder liners have their bore/grade and step
height determined at manufacture. The bore/
grade, red, blue (A) or (B), and step heights V
or Z together with the cylinder liner part number
and colour code are marked on the external
diameter of the cylinder liners. If cylinder(s) are
to be replaced, the replacement liner(s) must
have the same step height as the original
liner(s). Both step heights are available in red
(A) and blue (B) grades of cylinder liners.

+ GENERAL DATA, Engine - KV6
Petrol.
3.Check pistons for distortion and cracks.
NOTE: Piston grades A or B are stamped on
the crown of the piston.
4. Piston diameter check: Measure piston
diameter at right angles to gudgeon pin and 8
mm (0.3 in) from bottom of skirt.

+ GENERAL DATA, Engine - KV6
Petrol.
NOTE: Piston and connecting rods are only
supplied as an assembly.
CAUTION: Ensure pistons are retained with
their respective cylinder liners.
5.Position piston in cylinder liner and measure
clearance 20 mm (0.75 in) from bottom of
cylinder liner.

+ GENERAL DATA, Engine - KV6
Petrol.6. Piston ring gap: Position new top and second
compression piston rings 20 mm (0.75 in) from
top of cylinder bore and measure ring gaps.

+ GENERAL DATA, Engine - KV6
Petrol.
CAUTION: Ensure piston rings are kept
square to liner bore. Retain rings with the
piston fitted to the liner in which they were
checked.
7. Piston rings - refit:Using a suitable expander,
fit oil control spring.
8.With 'TOP' or identification markings to top of
piston, use an expander to fit piston rings in
sequence; oil control, 2nd and top
compression.
NOTE: The second compression ring is
stepped.
M12 6838

ENGINE - K SERIES KV6
OVERHAUL 12-3-89
13.Using sequence shown, progressively loosen
and remove 8 cylinder head bolts.
14.Remove cylinder head.
CAUTION: Support both ends of cylinder
head on blocks of wood.
15.Remove and discard cylinder head gasket.
CAUTION: Do not rotate crankshaft with RH
cylinder head fitted.
16.Fit cylinder liner clamps LRT-12-144 and
secure with cylinder head bolts.
CAUTION: Ensure that feet of clamps do not
protrude over bores.Refit
1.Clean cylinder head face.
CAUTION: Use suitable gasket removal
spray and a plastic scraper.
2.Remove bolts securing cylinder liner clamps
LRT-12-144 to cylinder block and remove
clamps.
CAUTION: Do not rotate crankshaft.
3.Clean cylinder block face and dowel holes.
4.Clean cylinder head bolts and wipe dry.
5.Lightly lubricate threads and beneath heads of
cylinder head bolts with clean engine oil.
6.Check that fitted height of dowels is between 10
to 11 mm (0.40 to 0.43 in) above cylinder block
top face. Replace dowels if fitted height is
incorrect.
7.Fit new cylinder head gasket onto cylinder
block with the word 'TOP' uppermost.
8.With assistance, fit cylinder head and carefully
position LH inlet to RH inlet manifold.
9.Carefully enter cylinder head bolts, DO NOT
DROP. Screw bolts into place by hand.

ENGINE - K SERIES KV6
OVERHAUL 12-3-93
18.Fit cylinder liner clamps LRT-12-144 and
secure with cylinder head bolts.
CAUTION: Ensure that feet of clamps do not
protrude over bores.
Refit
1.Clean cylinder head face.
CAUTION: Use suitable gasket removal
spray and a plastic scraper.
2.Remove bolts securing cylinder liner clamps
LRT-12-144 to cylinder block and remove
clamps.
CAUTION: Do not rotate crankshaft.
3.Clean cylinder block face, dowels and dowel
holes.
4.Clean cylinder head bolts and wipe dry.
5.Lightly lubricate threads and beneath heads of
cylinder head bolts with clean engine oil.6.Check that fitted height of dowels is between 10
to 11 mm (0.40 to 0.43 in) above cylinder block
top face. Replace dowels if fitted height is
incorrect.
7.Fit new cylinder head gasket onto cylinder
block with the word 'TOP' uppermost.
8.With assistance, fit cylinder head and carefully
position RH inlet to LH inlet manifold.
9.Carefully enter cylinder head bolts, DO NOT
DROP. Screw bolts into place by hand.
10.Using sequence shown, tighten cylinder head
bolts progressively to:
lStage 1 - 25 Nm (18 lbf.ft)
lStage 2 - 25 Nm (18 lbf.ft)
lStage 3 - 25 Nm (18 lbf.ft)
lStage 4 - Further 180°
11.Fit RH camshaft cover gasket.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - RH.
12.Remove and discard lower '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.

ENGINE - K SERIES KV6
12-3-98 OVERHAUL
13.Check cylinder head face for warping, across
centre and from corner to corner.

+ GENERAL DATA, Engine - KV6
Petrol.
14.Check cylinder head height.

+ GENERAL DATA, Engine - KV6
Petrol.
Note: Provided that cylinder head height is kept
within limits, cylinder heads may be refaced.
15.Check condition of valve springs and measure
free length of springs.

+ GENERAL DATA, Engine - KV6
Petrol.16.Remove carbon deposits from exhaust valve
guides using a 6 mm diameter reamer inserted
from combustion side of cylinder head.
17.Remove carbon from inlet valve guides, inlet
and exhaust valves and valve seat inserts.
Remove all loose carbon on completion.
18.Check and record existing valve stem
diameters 'A', replace any valve with stem
diameter less than specified.

+ GENERAL DATA, Engine - KV6
Petrol.
19.Check inlet and exhaust valve to guide
clearances 'B' using the following procedures.

ENGINE - K SERIES KV6
12-3-100 OVERHAUL
31.Check that fitted height of valve guide, 'A', is
6.00 mm (0.24 in).
32.Check condition of valve seats and existing
valves that are to be re-used.
33.Renew valve seat inserts as necessary.
CAUTION: Do not damage counterbore
when removing insert.
34.Cool replacement valve seat inserts using
liquid nitrogen and press into cylinder head in
one continuous operation.
CAUTION: Do not heat cylinder head.
Inserts must not stand proud of combustion
face on completion of cutting operation.
35.Cut valve seats using a suitable pilot and the
following cutters:
l15° - To cut first angle
l45° - Make final cut and remove any burrs
l60° - To narrow seat and obtain correct
valve seat width
36.Check valve seat width and face angle:
lSeat width - 'A' - Inlet = 1.2 mm (0.05 in);
Exhaust = 1.6 mm (0.06 in)
lValve face angle - 'B' - Inlet and exhaust =
45°
37.Lap each valve to its seat using grinding paste.38.Apply Prussian Blue to valve seat, insert valve
and press it into position several times without
rotating. Remove and check valve for even and
central seating: seating position shown by
Prussian Blue should be in the centre of valve
face: a: High towards stem, increase 60° cut
and restore seat width. b: Low towards edge,
increase 45° cut and restore seat width. Lap
and recheck valve seating.
39.Check valve stem fitted height - 'A'.

+ GENERAL DATA, Engine - KV6
Petrol.
CAUTION: If valve stem fitted height is
above service limit, fit new valve and re-
check. If still over limit, renew valve seat
insert.
40.Clean valve springs and lubricate valves.
Reassembly
1.Lubricate new valve stem oil seals with clean
engine oil.
2.Using tool LRT-12-071 fit new valve stem oil
seals.
3.Fit valves.
M12 7894
A

FUEL DELIVERY SYSTEM - PETROL
REPAIRS 19-2-29
Pump - fuel
$% 19.45.08
WARNING: If fuel tank is full, using a fuel
recovery appliance, drain excess fuel from fuel
filler neck until a level below height of fuel pump
is obtained.
Remove
1.Disconnect battery earth lead.
2.Open RH rear and tail doors.
3.Fold RH rear seat forward.
4.Remove 2 fasteners securing front and rear
carpets.
5.Pull back loadspace carpet from fuel pump
access panel.
6.Remove 6 screws securing access panel.
WARNING: Depressurise the system before
disconnecting any components. Fuel
pressure will be present in the system even
if the ignition has been switched off for
some time.
7.Remove access panel.
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
8.Disconnect multiplug and fuel hose from fuel
pump housing.
CAUTION: Always fit plugs to open
connections to prevent contamination.9.Use LRT-19-009 to remove locking ring from
fuel pump housing.
10.Remove fuel pump housing and discard sealing
ring.
Refit
1.Clean fuel pump housing and mating face on
fuel tank.
2.Fit new seal to fuel pump housing.
3.Fit fuel pump housing to fuel tank, fit and tighten
locking ring to 35 Nm (26 lbf.ft) using LRT-19-
009.
4.Connect multiplug and fuel hose to fuel pump
housing.
5.Fit access panel and secure with screws.
6.Position carpet and secure with fasteners.
7.Reposition rear seat.
8.Close rear and tail doors.
9.Connect battery earth lead.

STEERING
57-18 REPAIRS
Cable - key interlock
$% 57.40.51
Remove
1.Disconnect battery earth lead.
2.Remove front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
3.Loosen bolt securing cable clamp.
4.Disconnect cable from interlock mechanism.
5.Remove key from starter switch.
6.Remove steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
column.
7.Remove bolt securing steering column height
adjuster lever and remove lever.
NOTE: Thread is left handed.
8.Remove nut securing height adjuster clamp
bolt and remove bolt.
9.Collect plastic stop.10.Loosen union and disconnect cable from
column lock.
11.Release cable from 2 retaining clips.
12.Note the cable routing, manoeuvre cable from
under heater and steering column bracket.
13.Remove cable.

STEERING
REPAIRS 57-19
Refit
1.Position cable, align to heater and steering
column bracket and secure in retaining clips.
2.Align key interlock cable to column lock and
tighten union to 4 Nm (3 lbf.ft).
3.Fit height adjuster clamp bolt and tighten nut to
10 Nm (7.5 lbf.ft). Ensure bolt and plastic stop
are correctly located in slot in column bracket.
4.Fit height adjuster lever and tighten bolt 12 Nm
(9 lbf.ft). Ensure lever is in the fully up position
before tightening bolt. Hold clamp bolt nut to
prevent nut rotation.
5.Connect cable to interlock mechanism.
6.Check key interlock cable adjustment.

+ STEERING, ADJUSTMENTS, Cable
- key interlock - adjust.
7.Fit steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
column.
8.Fit front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
9.Connect battery earth lead.
Column assembly - inner & outer
$% 57.41.01
Remove
1.Disconnect battery earth lead.
2.Remove steering column multi purpose switch.

+ LIGHTING, REPAIRS, Switch -
combined direction indicator/headlight/
horn.
3.Disconnect multiplugs from ignition switch and
passive coil.
4.Remove 2 screws securing steering column
aperture trim and remove trim.