2001 LAND ROVER FREELANDER ird

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 12-3-53
Sump - reseal
$% 12.60.38
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.

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

+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.
4.Remove 3 bolts securing RH splash shield to
body and remove shield.
5.Remove 4 nuts securing engine oil cooler to
mounting bracket and position oil cooler aside.6.Remove bolt securing dipstick tube to cylinder
block.
7.Depress and hold down dipstick collar, remove
dipstick tube from sump.
8.Remove 3 bolts securing IRD support bracket
to sump.
9.Using sequence shown and noting their fitted
position, remove 10 bolts securing sump to
lower crankcase.
M12 6614
M12 7916
M12 6672

ENGINE - K SERIES KV6
12-3-54 REPAIRS
10.Using a mallet, gently tap sump sideways to
break sealant bond, remove sump.
CAUTION: Do not lever between sump and
lower crankcase.
Refit
1.Using a suitable cleaning solvent, clean sump
and mating face on lower crankcase. DO NOT
use a metal scraper on sealing surfaces.
2.Apply a 2 mm (0.1 in) bead of sealant, Part No.
STC 4600 along centre of sump flange, then
spread to an even film using a roller.
CAUTION: To avoid contamination,
assembly must be completed immediately
after application of sealant.
3.Position sump, fit bolts and tighten
progressively in the sequence shown to 35 Nm
(26 lbf.ft).
4.Fit bolts securing IRD support bracket to sump
and tighten to 88 Nm (65 lbf.ft).
5.Position engine oil cooler to mounting bracket,
fit and tighten nuts to 25 Nm (18 lbf.ft).
6.Position dipstick tube to sump and cylinder
block, fit bolt and tighten to 9 Nm (7 lbf.ft).
7.Fit splash shield and secure with bolts.
8.Fill engine with correct quantity and grade of oil.

+ MAINTENANCE, MAINTENANCE,
Engine Oil and Filter – KV6.
9.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
10.Connect battery earth lead.
Switch - oil pressure
$% 12.60.50
Remove
1.Disconnect battery earth lead.
2.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Remove RH front road wheel.
4.Remove 3 bolts securing RH splash shield to
body and remove shield.
5.Place container below oil pressure switch to
collect spillage.
6.Disconnect multiplug from oil pressure switch.
7.Remove oil pressure switch and discard
sealing washer.
M12 6675
10
9
135
8
4
7
26
M12 6614

ENGINE - K SERIES KV6
12-3-62 REPAIRS
30.Depress and hold down dipstick tube locking
collar, remove dipstick tube from engine sump.
31.Remove rubber blanking plug from around
camshaft timing belt tensioner.
32.Remove 3 bolts securing engine front mounting
plate and lifting bracket to cylinder block.
33.Remove bolt securing lifting bracket to RH
cylinder head and remove lifting bracket.34.Remove 2 bolts securing IRD support bracket
to engine front mounting plate.
35.Remove 5 bolts and 2 pillar bolts securing
engine front mounting plate to cylinder block.
36.With care, release and remove front mounting
plate from engine.
37.Insert a suitable 1.5 mm diameter pin through
hole in tensioner body and into hole in plunger.
NOTE: If holes in body and plunger are not
aligned, move tensioner backplate using a
suitable broad bladed screwdriver; this will
move plunger sufficiently to enable pin to be
inserted.

ENGINE - K SERIES KV6
REPAIRS 12-3-65
11.With assistance, position tensioner, fit new
Patchlok bolts and tighten to 25 Nm (18 lbf.ft).
CAUTION: Ensure tensioner plunger is
contacting underside of tensioner
backplate.
12.Remove tools LRT-12-175 from rear timing belt
gears.
13.Fit tools LRT-12-196 to both 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.
14. Tighten front inlet camshaft gear bolts to:
lStage 1 - 27 Nm (20 lbf.ft)
lStage 2 - Further 90°
15.Remove tools LRT-12-196 from both inlet
camshaft gears and exhaust camshafts.
16.Remove wedge from between drive belt and oil
pump belt guard.
17.Remove 1.5 mm diameter pin from tensioner.
18.Fit rubber blanking plug around tensioner.
19.Remove timing pin LRT-12-232.
20.Clean exhaust camshaft front cap seal
locations and fit new cap seals.
CAUTION: The sealing edge of the cap seal
and mating face must be clean and dry.
21.Position engine front mounting plate and
manoeuvre plate into position. Fit bolts but do
not tighten at this stage.22.Fit bolts securing IRD support bracket to front
mounting plate but do not tighten at this stage.
23.Tighten bolts in the sequence shown:
lBolt No. 1 - 25 Nm (18 lbf.ft)
lBolt No. 5 - 45 Nm (33 lbf.ft)
lBolts Nos. 2, 3, 4, 6 and 7 - 85 Nm (63 lbf.ft)
24.Position engine lifting bracket, fit bolts securing
lifting bracket and front mounting plate to
cylinder block and RH cylinder head. Tighten
M10 bolts to 45 Nm (33 lbf.ft) and M8 bolt to 25
Nm (18 lbf.ft).
25.Clean end of dipstick tube.
26.Position dipstick tube to sump and cylinder
block, fit bolt and tighten to 9 Nm (7 lbf.ft).
27.Position A/C compressor to front mounting
plate and cylinder block, align heat shield, fit
and tighten bolts to 25 Nm (18 lbf.ft).
28.Clean lower timing belt cover.
29.Position lower timing belt cover, fit and tighten
bolts to 9 Nm (7 lbf.ft).
30.Clean crankshaft pulley.
31.Fit crankshaft pulley to crankshaft gear and
ensure that the indent on pulley locates over
the lug on crankshaft gear.
32.Fit crankshaft pulley bolt and washer, position
LRT-12-161 with LRT-12-199 into crankshaft
pulley. Tighten pulley bolt to 160 Nm (118
lbf.ft).
33.Remove tools LRT-12-161 and LRT-12-
199from crankshaft pulley.
34.Clean ancillary drive belt tensioner.
35.Position ancillary belt tensioner, fit bolts and
tighten to 25 Nm (18 lbf.ft).
36.Clean LH and RH front timing belt covers.
37.Position LH and RH front timing belt covers, fit
and tighten bolts to 4 Nm (3 lbf.ft).
38.Clean idler pulley, position pulley to engine
front mounting plate and tighten Allen bolt to 45
Nm (33 lbf.ft).
39.Position alternator to front mounting plate.

ENGINE - K SERIES KV6
OVERHAUL 12-3-111
27.Remove 5 bolts and 2 pillar bolts securing
engine front mounting plate to cylinder block.
28.Remove 2 bolts securing IRD support bracket
to engine front mounting plate.
29.With care, release and remove front mounting
plate from engine.
30.Fit a suitable 1.5 mm diameter pin through hole
in tensioner body and into hole in plunger.
NOTE: If holes in body and plunger are not
aligned, move tensioner backplate using a
broad bladed screwdriver; this will move the
plunger sufficiently to align the holes and allow
the pin to be inserted.31.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.
32.If camshaft timing belt is to be refitted, mark
direction of rotation on timing belt before
removal.
33.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.
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.
34.Remove and discard LH and RH exhaust
camshaft cap seals.

ENGINE - K SERIES KV6
OVERHAUL 12-3-113
11.Position an Allen key in tensioner backplate
and hold tensioner pulley against timing belt.
12.With assistance, position timing belt tensioner,
fit new Patchlok bolts and tighten to 25 Nm (18
lbf.ft).
CAUTION: Ensure tensioner plunger is
contacting underside of tensioner
backplate.
13.Remove tools LRT-12-175 from rear timing belt
gears.
14.Fit tools LRT-12-196 to both 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.
15.Tighten front inlet camshaft gear bolts to:
lStage 1 - 27 Nm (20 lbf.ft)
lStage 2 - Further 90°
16.Remove tools LRT-12-196 from both inlet
camshaft gears and exhaust camshafts.17.Remove wedge from between drive belt and oil
pump belt guard.
18.Remove 1.5 mm diameter pin from tensioner.
19.Clean exhaust camshaft front cap seal
locations and fit new cap seals.
CAUTION: The sealing edge of the cap seal
and mating face must be clean and dry.
20.Position engine front mounting plate and
manoeuvre plate into position; fit bolts but do
not tighten at this stage.
21.Fit bolts securing IRD support bracket to front
mounting plate; do not tighten bolts at this
stage.
22.Tighten bolts in the sequence shown:
lM10 bolt - No.1 - 25 Nm (18 lbf.ft)
lM10 bolt - No. 5 - 45 Nm (33 lbf.ft)
lBolts Nos. 2, 3, 4, 6 and 7 - 85 Nm (63 lbf.ft)
23.Position engine lifting bracket, fit bolts securing
lifting bracket and front mounting plate to
cylinder block and RH cylinder head and
tighten to:
lM8 bolt - 25 Nm (18 lbf.ft)
lM10 bolts - 45 Nm (33 lbf.ft)
24.Fit rubber blanking plug around tensioner.
25.Clean end of dipstick tube.
26.Position dipstick tube to sump and cylinder
block, fit bolt and tighten to 9 Nm (7 lbf.ft).
27.Clean lower timing belt cover.
28.Position lower timing belt cover, fit and tighten
bolts to 9 Nm (7 lbf.ft).
29.Remove timing pin LRT-12-232.
30.Clean crankshaft pulley.
31.Fit crankshaft pulley to crankshaft gear and
ensure that the indent on pulley locates over
the lug on crankshaft gear.
32.Fit crankshaft pulley bolt and washer, position
LRT-12-161 with LRT-12-199 into crankshaft
pulley. Tighten pulley bolt to 160 Nm (118
lbf.ft).
33.Remove tools LRT-12-161 and LRT-12-199.
34.Clean ancillary drive belt tensioner.