2001 LAND ROVER FREELANDER Workshop Manual

COOLING SYSTEM - K SERIES KV6
26-3-4 REPAIRS
Radiator assembly
$% 26.40.01
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.

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

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
4. Models without A/C: Remove bumper
valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5. Models without A/C:Remove 2 bolts securing
PAS fluid cooler to armature.
6. Models without A/C: Remove 4 nuts and 4
bolts securing armature to body and remove
armature.
7. Models with A/C: Remove A/C condenser.

+ AIR CONDITIONING, REPAIRS,
Condenser.
8.Release clips and remove top and bottom
hoses.
CAUTION: Always fit plugs to open
connections to prevent contamination.
9.Release clip and remove expansion hose from
radiator.10. If fitted:Remove 2 bolts and 4 scrivets securing
LH and RH radiator baffles and remove baffles.
11.Remove radiator upper retaining pegs from
bonnet locking platform. Ease top of radiator
forward.
12.Remove 4 bolts securing fan cowl to radiator.
13.Remove 2 cowl retaining clips from radiator.
M26 0947

COOLING SYSTEM - K SERIES KV6
REPAIRS 26-3-5
14.Release radiator from lower mountings and
remove from vehicle.
15.Remove radiator upper mounting extension
brackets.
16.Remove 4 rubber mountings from radiator.Refit
1.Fit mounting rubbers to radiator.
2.Fit upper support brackets to radiator.
3.Position fan cowl to radiator, fit and tighten
bolts to 5 Nm (4 lbf.ft).
4.Secure fan cowl to radiator with clips.
5.Fit radiator and engage lower mountings in
chassis.
6.Fit radiator upper mountings to bonnet locking
platform.
7. If fitted:Position LH and RH radiator baffles,
secure with scrivets, fit and tighten top bolts to
5 Nm (4 lbf.ft).
8.Connect expansion tank hose and secure with
clip.
9.Connect bottom and top hoses to radiator
secure with clips.
10. Models with A/C: Fit A/C condenser.

+ AIR CONDITIONING, REPAIRS,
Condenser.
11. Models without A/C: Position armature, fit and
tighten 4 nuts and bolts securing armature to
body.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
12. Models without A/C: Align PAS fluid cooler
and tighten bolts to 8 Nm (6 lbf.ft).
13. Models without A/C: Fit bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
14.Refill cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
15.Fit acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
16.Connect battery earth lead.
M26 0946

COOLING SYSTEM - K SERIES KV6
26-3-6 REPAIRS
Thermostat
$% 26.45.01
Remove
1.Disconnect battery earth lead.
2.Drain cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
3.Remove inlet manifold chamber.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.
4.Remove 2 bolts securing RH fuel rail to inlet
manifold. Remove injector protection cover if
fitted.
5.Release 2 clips securing engine harness to rear
engine lifting bracket and bracket on RH inlet
manifold.
6.Release clip and disconnect bottom hose from
thermostat housing.
7.Loosen clip and disconnect heater hose from
thermostat housing.8.Release clip and disconnect top hose from
coolant elbow.
9.Remove bolt securing thermostat housing and
coolant elbow to cylinder block.
10.Remove coolant elbow from cylinder block.
11.Remove thermostat housing and coolant pipe
from cylinder block.
12.Release clip and remove coolant pipe from
thermostat housing.
13.Remove and discard 4 'O' rings from
thermostat housing, coolant elbow and coolant
pipe.
Refit
1.Lubricate new 'O' rings with rubber grease and
fit to sealing grooves in thermostat housing,
coolant elbow and coolant pipe.
2.Fit coolant pipe into thermostat housing, ensure
clip connectors are uppermost.
3.Position thermostat housing and coolant pipe
above cylinder block, engage coolant pipe in
cylinder block and press thermostat housing
firmly into position. Ensure mounting flange on
thermostat housing is aligned to bolt hole in
cylinder block.
4.Fit coolant elbow into cylinder block, press
firmly into place. Ensure mounting flange is
aligned correctly to thermostat housing flange.
5.Fit bolt to coolant elbow and thermostat
housing flanges. Tighten bolt to 18 Nm (13
lbf.ft).
6.Connect top hose to coolant elbow and secure
with clip.
7.Connect heater and bottom hoses to
thermostat housing, secure with clips.
8.Position and secure engine harness to brackets
with clips.
9.If fitted, position injector protection cover to RH
fuel rail, fit and tighten bolts to 9 Nm (7 lbf.ft).
10.Fit inlet manifold chamber.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.
11.Fill cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
12.Connect battery earth lead.

COOLING SYSTEM - K SERIES KV6
REPAIRS 26-3-7
Coolant pump
$% 26.50.01
Remove
1.Disconnect battery earth lead.
2.Drain cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
3.Remove camshaft timing belt.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
4.Remove and discard 7 bolts securing coolant
pump to cylinder block.
5.Release coolant pump from cylinder block and
remove.
6.Remove and discard 'O' ring from coolant
pump.Refit
1.Clean coolant pump and mating face of cylinder
block.
2.Lubricate new 'O' ring with rubber grease and fit
to coolant pump.
3.Fit coolant pump to cylinder block. Fit new bolts
and tighten progressively in the sequence
illustrated to 9 Nm (7 lbf.ft).
4.Fit camshaft timing belt.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft timing belt.
5.Fill cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
6.Connect battery earth lead.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-1
MANIF OLDS & EX HAUST SYSTEMS - K SERIES KV6 REPAIRS
Front pipe - Non NAS
$% 30.10.09
Remove
1.Remove gear selector knob.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gear knob.
2.Release clips securing selector lever trim panel
to centre console and move trim panel aside.
3.Release and disconnect post catalyst HO2S
multiplug.
4.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Release grommet and withdraw HO2S harness
multiplug through grommet aperture.6.Remove nut securing exhaust heat shield to
mounting bracket.
7.Remove 2 nuts securing heat shield to IRD
pinion housing.
8.Remove heat shield.
9.Remove 4 nuts securing front pipe flanges to
exhaust manifolds.
10.Release manifold flanges.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-2 REPAIRS
11.Remove 3 nuts securing front pipe to
intermediate pipe.
12.Release intermediate pipe from front pipe.
13.Remove gasket.
14.Remove exhaust front pipe.
15.Remove HO2S.Refit
1.Clean HO2S and mating face.
2.If refitting existing HO2S, apply anti-seize
compound to HO2S threads.
3.Fit HO2S and tighten to 55 Nm (41 lbf.ft)using
tool LRT-19-014.
4.Clean exhaust pipe and manifold flanges.
5.Fit exhaust front pipe.
6.Using new gasket, connect intermediate pipe to
front pipe, fit nuts and tighten to 50 Nm (37
lbf.ft).
7.Position LH exhaust manifold flange to front
pipe, fit and tighten nuts to 50 Nm (37 lbf.ft).
8.Position RH exhaust manifold flange to front
pipe, fit and tighten nuts to 50 Nm (37 lbf.ft).
9.Fit exhaust heatshield and fit nuts finger tight.
10.Tighten nut securing exhaust heatshield to
exhaust mounting bracket to 45 Nm (33 lbf.ft).
11.Tighten nuts securing exhaust heatshield to
pinion housing to 25 Nm (18 lbf.ft).
12.Feed HO2S harness through grommet aperture
and secure grommet.
13.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
14.Connect HO2S multiplug.
15.Fit trim panel and gaiter to centre console and
secure clips.
16.Fit gear selector knob.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gear knob.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-3
Front pipe - NAS
$% 30.10.09
Remove
1.Disconnect battery earth lead.
2.Remove intermediate pipe and silencer.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Intermediate
pipe - NAS.
3.Remove 3 bolts securing heat shield and
remove heat shield from front pipe.
4.Remove 2 bolts securing pipe clamp and
remove lower half of clamp.5.Remove 2 nuts securing front pipe to manifold.
6.Remove bolt securing front pipe to bracket and
remove front pipe. Discard gasket.
Refit
1.Clean front pipe and manifold mating faces.
2.Using a new gasket, fit front pipe and fit but do
not tighten nuts.
3.Fit bolt securing front pipe to bracket but do not
tighten.
4.Fit lower half of pipe clamp, fit bolts but do not
tighten.
5.Fit intermediate pipe and silencer.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Intermediate
pipe - NAS.
6.Tighten nuts securing front pipe to manifold to
50 Nm (37 lbf.ft).
7.Tighten bolts securing clamp to 10 Nm (7 lbf.ft).
8.Tighten bolt securing front pipe to bracket to 25
Nm (18 lbf.ft).
9.Connect battery earth lead.