2001 LAND ROVER FREELANDER tow

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

ENGINE - K SERIES KV6
OVERHAUL 12-3-101
4.Fit spring and spring cap.
5.Position LRT-12-034 and adapter LRT-12-
034/1to spring cap and compress valve spring.
6.Fit collets.
7.Release valve spring and remove tool LRT-12-
034.
8.Using a wooden dowel and mallet, lightly tap
top of each valve two or three times to seat
valves and collets.
9.Thoroughly clean and lubricate hydraulic
tappets with clean engine oil. Fit hydraulic
tappets to original bores in cylinder head.
10.Ensure that mating faces of camshaft carrier
and cylinder head are clean and dry.
11.Lubricate camshafts and bearing journals with
clean engine oil.
12.Position camshafts in cylinder head with rear
timing gear drive slots in each camshaft facing
towards the centre as shown.
CAUTION: Ensure camshafts are in their
correct fitted locations. Camshafts are
colour coded - Inlet - Orange; Exhaust -
Blue.13.Apply continuous thin beads of sealant, Part
No. STC 4600, to paths on camshaft carrier as
shown. Spread sealant to an even film using a
roller.
CAUTION: To avoid contamination,
assembly should be completed immediately
after application of sealant.
14.Position camshaft carrier, fit and progressively
tighten bolts in the sequence shown to 10 Nm
(7.5 lbf.ft).

INTERMEDIATE REDUCTION DRIVE
41-24 REPAIRS
Seal - drive shaft - LH - K1.8
$% 41.29.08
Remove
1.Remove LH drive shaft.

+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - LH.
2.Carefully remove oil seal from differential
housing, discard oil seal.
Refit
1.Thoroughly clean oil seal recess in differential
housing, splines and oil seal running surface on
drive shaft.
2.Fit handle LRT-37-027 into seal replacer
adaptor, LRT-37-032.
3.Position new oil seal onto LRT-37-032 with
sealing lip facing towards differential housing.
4.Carefully drift oil seal into housing until fully
seated in recess.5.Fully insert oil seal protector tool, Unipart TRV
100060, into differential oil seal so that oil seal
lip is protected and that the split end of tool is
butted correctly.
6.Fit LH drive shaft.

+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - LH.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-25
Seal - driveshaft - RH
$% 41.29.09
Remove
1.Remove RH drive shaft.

+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - RH.
2.Carefully remove and discard oil seal, take care
not to damage oil seal recess.
Refit
1.Clean oil seal recess.
2.Locate seal on tool LRT-37-031 and replacer
LRT-37-027 with sealing lip facing towards
housing.
3.Carefully drift oil seal into housing until fully
seated in recess.
4.Fit RH drive shaft.

+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - RH.
Seal - pinion gear housing - Td4
$% 41.29.11
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Drain fluid from IRD.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
4.Raise one rear wheel for rotation of propeller
shaft to access bolts.
5.Reference mark front propeller shaft for
reassembly.
6.Remove 6 nuts and bolts securing propeller
shaft to IRD drive flange.
7.Release propeller shaft from IRD drive flange
and tie shaft aside.
CAUTION: Care must be taken to support
the Tripode joint when removed from the
IRD unit. To avoid damage to gaiter or steel
can, the joint should not be allowed to fully
extend or be dropped.

FRONT SUSPENSION
60-6 REPAIRS
Refit
1.Clean hub and drive flange.
2.Support hub on tool LRT-54-016 and press in
new bearing using LRT-54-015.
CAUTION: One side of the bearing is
magnetic. The magnetic side is identifiable
by the application of a matt black finish. The
magnetic side must face towards the
inboard side of the vehicle. Before fitting
the bearing, ensure the magnetic face is
clean. The bearing must be handled with
extreme care.
3.Fit circlip to hub.
4.Fit brake disc shield, fit bolts and tighten to 8.5
Nm (6.5 lbf.ft).
5.Support bearing on tool LRT-54-015 and press
drive flange into bearing using LRT-54-014.
6.Clean drive shaft.7.Fit hub assembly to lower joint, fit new nut and
tighten to 65 Nm (48 lbf.ft).
8.Fit drive shaft to hub.
9.Fit hub to damper, fit nuts and bolts and tighten
to 205 Nm (151 lbf.ft).
10.Clean brake disc to drive flange mating faces.
11.Fit disc to drive flange, align reference marks, fit
screws and tighten to 5 Nm (4 lbf.ft).
12.Clean mating faces of caliper and hub.
13.Position caliper to brake disc fit bolts and
tighten to 100 Nm (74 lbf.ft).
14.Fit brake hose to abutment bracket and fit clip.
15.Clean ABS sensor, smear sensor with an anti-
seize grease and fit sensor to hub.
CAUTION: Ensure ABS sensor is fully
located into hub, so that sensor touches
pole wheel teeth.
16.Fit ABS sensor lead to bracket.
17.Fit new drive shaft nut and tighten to 400 Nm
(295 lbf.ft). Stake nut to shaft.
18.Stake drive shaft hub nut.
19.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
20.Remove stands and lower vehicle.

REAR SUSPENSION
64-4 REPAIRS
21.Remove circlip from bearing.
22.Position hub to press and press out bearing
using tool LRT-54-015 and LRT-54-017,
discard bearing.
CAUTION: Never re-use existing bearing.Refit
1.Clean hub and drive flange.
2.Support hub on tool LRT-54-016 and press in
new bearing using LRT-54-015.
CAUTION: One side of the bearing is
magnetic. The magnetic side is identifiable
by the application of a matt black finish. The
magnetic side must face towards the
inboard side of the vehicle. Before fitting
the bearing, ensure the magnetic face is
clean. The bearing must be handled with
extreme care.
3.Fit circlip to hub.
4.Fit hub to vice, fit backplate and tighten bolts to
45 Nm (33 lbf.ft).
5.Support bearing on tool LRT-54-015 and press
drive flange into bearing using LRT-54-014.
6.Fit hub assembly to drive shaft.

INTERIOR TRIM COMPONENTS
76-3-14 REPAIRS
Fascia - up to 04MY
$% 76.46.23
Remove
1.Remove front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
2.Remove rotary coupler.

+ RESTRAINT SYSTEMS, REPAIRS,
Rotary coupler - (SRS) air bag system.
3.Disconnect 4 multiplugs from wiper/indicator
switch.
4.Loosen clamping screw and remove wiper/
indicator switch.
5.Remove 2 screws from steering column lower
finisher and remove finisher.6.Open drivers glove box lid and remove fuse box
cover.
7.Disconnect 2 multiplugs from fusebox.
8.Close glove box.
9.Remove clock.

+ INSTRUMENTS, REPAIRS, Clock.
10.Remove both 'A' post upper trim finishers.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim finisher - 'A' post - upper -
renew.
11. Models without passenger airbag: Remove
fascia stowage box.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Stowage box - fascia.
12. Models with passenger airbag: Remove
passenger airbag.

+ RESTRAINT SYSTEMS, REPAIRS,
Air bag - fascia - passenger - up to 04MY.

INTERIOR TRIM COMPONENTS
76-3-18 REPAIRS
Refit
1.Fit fascia and coin tray mats.
2.Fit immobilisation ECU to fascia and secure
with nuts.
3.Connect multiplug to immobilisation ECU.
4.Fit switch blank.
5.Fit glove box locks to fascia and secure with
screws.
6.Fit glove box and secure with screws.
7.Fit glove box lamp and mat.
8.Fit glove box lids and secure hinge pins.
9.Fit face level vents and seals to fascia.
10.Fit centre bracket and secure with screws.
11. Models without passenger airbag: Fit grab
handle and secure with nuts.
12.Fit instrument pack lower cover and secure with
screws.
13.Fit instrument pack to fascia and secure with
screws.
14.Fit fascia harness to fascia and secure with
clips.
15.Connect Lucars to glove box lamp and switch.
16.Connect multiplugs to mirror switch and
headlamp levelling switch.
17.Fit mirror switch and headlamp levelling switch.
18.Connect multiplugs to instrument pack.
19.Fit instrument pack upper cover and secure
with screws.
20.Connect multiplugs to switches on instrument
bezel finisher, fit bezel and secure with screws.
21.With assistance fit fascia to vehicle and secure
with bolts.22.Connect fascia harness multiplugs to main
harness.
23. Models with passenger airbag: Fit passenger
airbag.

+ RESTRAINT SYSTEMS, REPAIRS,
Air bag - fascia - passenger - up to 04MY.
24. Models without passenger airbag: Fit fascia
stowage box.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Stowage box - fascia.
25.Fit 'A' post upper trim finishers.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim finisher - 'A' post - upper -
renew.
26.Fit clock.

+ INSTRUMENTS, REPAIRS, Clock.
27.Open drivers glove box lid and remove fuse box
cover.
28.Connect multiplugs to fusebox.
29.Fit fusebox cover and close glove box lid.
30.Fit steering column lower cover and secure with
screws.
31.Fit wiper/indicator switch and tighten clamping
screw.
32.Connect multiplugs to wiper/indicator switch.
33.Fit rotary coupler.

+ RESTRAINT SYSTEMS, REPAIRS,
Rotary coupler - (SRS) air bag system.
34.Fit front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.