2001 LAND ROVER FREELANDER Workshop Manual

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-4 REPAIRS
Intermediate pipe - Non NAS
$% 30.10.11
Remove
1.Raise vehicle on 4 post ramp.
2.Loosen tail pipe clamp nut and release tail pipe
from intermediate pipe.
3.Remove 3 nuts securing front pipe to
intermediate pipe.
4.Release intermediate pipe from front pipe.
5.Remove and discard gasket.
6.Release rubber mounting from intermediate
pipe.
7.With assistance release and remove
intermediate pipe.Refit
1.Clean intermediate pipe/silencer, front pipe and
tail pipe mating faces.
2.Fit new gasket to front pipe flange.
3.With assistance fit intermediate pipe to tail pipe
and front pipe.
4.Fit nuts to intermediate pipe flange and tighten
to 60 Nm (44 lbf.ft).
5.Tighten tail pipe clamp nut to 55 Nm (41 lbf.ft).
6.Fit intermediate pipe to rubber mounting.
7.Lower vehicle.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-5
Intermediate pipe - NAS
$% 30.10.11
Remove
1.Raise vehicle on 4 post ramp.
2.Remove tail pipe and silencer.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Tail pipe &
silencer.
3.Remove 2 nuts securing intermediate pipe to
front pipe.
4.Loosen nut securing intermediate pipe clamp to
catalyst.
5.Release intermediate pipe from mounting.
6.Release and remove intermediate pipe.
7.Remove and discard gasket.Refit
1.Clean intermediate pipe and mating faces.
2.Fit new gasket to front pipe flange.
3.Fit intermediate pipe and connect mounting.
4.Tighten intermediate pipe flange nuts to 60 Nm
(44 lbf.ft).
5.Tighten clamp nut to 55 Nm (40 lbf.ft).
6.Fit tail pipe and silencer.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Tail pipe &
silencer.
7.Lower vehicle.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-6 REPAIRS
Tail pipe & silencer
$% 30.10.22
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Loosen tail pipe clamp nut.
3.Release 2 rubber mountings from tail pipe.
4.Remove tail pipe.Refit
1.Clean mating faces of tail pipe and intermediate
pipe.
2.Fit tail pipe and connect rubber mountings.
3.Tighten tail pipe clamp nut to 55 Nm (41 lbf.ft).
4.Remove stands and lower vehicle.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-7
Heat shield - A/C compressor - KV6 - NAS
$% 30.10.32
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Using a 3/8” square drive socket bar, raise
ancillary drive belt tensioner and release drive
belt from alternator pulley.
4.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Remove 3 bolts securing A/C compressor to
fixing brackets and position compressor aside.
6.Remove compressor heat shield.Refit
1.Clean compressor and mounting bracket
mating faces.
2.Fit compressor heat shield.
3.Position compressor to mounting and align
heat shield. Fit and tighten bolts to 25 Nm (18
lbf.ft).
4.Using a 3/8" square drive socket bar, raise
ancillary drive belt tensioner and fit drive belt to
pulleys.
5.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
6.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
7.Connect battery earth lead.
M30 1142

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-8 REPAIRS
Gasket - inlet manifold - LH
$% 30.15.08
Remove
1.Disconnect battery earth lead.
2.Drain cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
3.Remove fuel rail.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Fuel rail - KV6 - Non
NAS.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Fuel rail - KV6 - NAS.
4.Depress locking collar and release breather
hose from LH inlet manifold.
5.Release clip and disconnect coolant hose from
LH inlet manifold.
6.Progressively loosen and remove 7 bolts
securing LH inlet manifold to cylinder head.
7.Remove inlet manifold and discard gasket.Refit
1.Clean inlet manifold and cylinder head mating
faces.
2.Fit new inlet manifold gasket to cylinder head,
position inlet manifold, fit and tighten bolts to 25
Nm (18 lbf.ft).
3.Connect breather hose to LH inlet manifold.
4.Connect coolant hose to inlet manifold and
secure clip.
5.Fit fuel rail.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Fuel rail - KV6 - Non
NAS.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Fuel rail - KV6 - NAS.
6.Fill cooling system.

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

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-9
Gasket - exhaust manifold - RH - Non
NAS
$% 30.15.16
Remove
1.Disconnect battery earth lead.
2.Release RH HO2S multiplug from coolant rail
bracket and disconnect multiplug.
3.Remove bolt securing upper RH engine steady
to top arm.
4.Loosen bolt securing upper RH engine steady
to body, pivot engine steady away from top
arm.
5.Raise vehicle on a ramp.
6.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
7.Remove exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - Non
NAS.8.Remove bolt securing lower engine steady to
sump mounting bracket.
9.Loosen bolt securing lower engine steady to
subframe, pivot steady away from sump
mounting bracket.
10.Remove cable tie and release gear selector
cable from clip on body.
11.Remove 2 bolts securing IRD heat shield to
lower engine steady mounting bracket.
12.Remove nut securing heat shield to IRD pinion
housing.
13.Remove nut securing heat shield to IRD
housing and remove heat shield.
M30 0996
M12 6597

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-10 REPAIRS
14.Remove 4 nuts securing RH exhaust manifold
to cylinder head.
15.Remove exhaust manifold, remove and discard
gasket.
Refit
1.Clean exhaust manifold and mating face on
cylinder head.
2.Fit new exhaust manifold gasket, position
exhaust manifold, fit nuts and tighten to 45 Nm
(33 lbf.ft).
3.Position heat shield to IRD unit.
4.Fit nut securing heat shield to IRD housing and
tighten to 45 Nm (33 lbf.ft).
5.Fit nut securing heat shield to IRD pinion
housing and tighten to 25 Nm (18 lbf.ft).
6.Fit 2 bolts securing heat shield to lower engine
steady mounting bracket and tighten to 9 Nm (7
lbf.ft).
7.Fit gear selector cable in body clip and secure
with cable tie.
8.Position lower engine steady to sump
mounting, fit and tighten bolt to 100 Nm (74
lbf.ft).
9.Tighten bolt securing lower engine steady to
subframe to 100 Nm (74 lbf.ft).
10.Fit exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - Non
NAS.
11.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
12.Lower vehicle on ramp.
13.Connect RH HO2S multiplug, secure multiplug
in coolant rail bracket.
14.Position upper RH engine steady to top arm, fit
and tighten bolt to 100 Nm (74 lbf.ft).
15.Tighten bolt securing upper RH engine steady
to body to 100 Nm (74 lbf.ft).
16.Connect battery earth lead.
Gasket(s) - exhaust manifold - RH - KV6 -
NAS
$% 30.15.16
Remove
1.Disconnect battery earth lead.
2.Remove RH catalytic converter.

+ EMISSION CONTROL, REPAIRS,
Catalytic converter - RH - KV6 - NAS.
3.Remove 4 nuts securing exhaust manifold to
cylinder head, remove manifold and discard
gasket.
Refit
1.Clean exhaust manifold and mating face.
2.Using new gasket, fit exhaust manifold and
tighten nuts to 45 Nm (33 lbf.ft).
3.Fit RH catalytic converter.

+ EMISSION CONTROL, REPAIRS,
Catalytic converter - RH - KV6 - NAS.
4.Connect battery earth lead.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-11
Gasket - exhaust manifold - LH - Non
NAS
$% 30.15.17
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Release HO2S multiplug from support bracket
on LH camshaft cover, disconnect multiplug.
4.Raise vehicle on ramp.
5.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
6.Remove 2 nuts securing front exhaust pipe to
manifold flange.
7.Lower vehicle on ramp.8.Release HO2S lead from clip on cylinder block.
Remove 4 nuts securing exhaust manifold to
cylinder head, remove manifold and discard
gasket.
Refit
1.Clean exhaust manifold and mating face on
cylinder head.
2.Fit new exhaust manifold gasket to cylinder
head.
3.Position exhaust manifold to cylinder head, fit
and tighten nuts to 45 Nm (33 lbf.ft).
4.Raise vehicle on ramp.
5.Position LH exhaust manifold flange to front
pipe, fit and tighten nuts to 50 Nm (37 lbf.ft).
6.Secure HO2S lead in clip on cylinder block.
7.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
8.Lower vehicle on ramp.
9.Connect HO2S multiplug and secure to support
bracket.
10.Fit engine acoustic cover.

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