2001 LAND ROVER FREELANDER drain bolt

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
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 30-3-23
Gasket - inlet manifold - RH
$% 30.15.43
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.Release clip and disconnect coolant hose from
RH inlet manifold.
5.Depress locking collar and release breather
hose from RH inlet manifold.
6.Progressively loosen and remove 7 bolts
securing RH inlet manifold to cylinder head.
7.Remove inlet manifold and gasket.
8.Remove bolt securing coolant breather hose
mounting bracket to inlet manifold and remove
bracket.Refit
1.Clean inlet manifold and cylinder head face.
2.Position coolant/breather hose bracket to inlet
manifold, fit and tighten bolt to 9 Nm (7 lbf.ft).
3.Fit new inlet manifold gasket to cylinder head,
position inlet manifold, fit and tighten bolts to 25
Nm (18 lbf.ft).
4.Connect coolant hose to inlet manifold and
secure clip.
5.Connect breather hose to manifold and secure
into collar.
6.Fit fuel rail.

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

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

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

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-3
REPAIRS
Intermediate reduction drive (IRD) unit -
Td4
$% 41.25.01.99
Remove
1.Disconnect battery earth lead.
2.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.
3.Remove rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
4.Remove exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - front.
5.Drain fluid from IRD.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
6.Drain gearbox fluid.

+ MANUAL GEARBOX - GETRAG,
ADJUSTMENTS, Gearbox oil - drain and
refill.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
7.Remove 3 bolts securing RH splash shield to
body and remove shield.8.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release drive shaft from
IRD.
9.With assistance, pull hub outwards and release
drive shaft from IRD.
10.Remove and discard drive shaft circlip.
11.Reference mark front propeller shaft for
reassembly.
12.Raise one rear wheel for rotation of propeller
shaft to access bolts.

INTERMEDIATE REDUCTION DRIVE
41-6 REPAIRS
Refit
1.Clean mating faces of IRD and gearbox.
2.Lubricate and fit new 'O' ring
3.With assistance, fit IRD.
4.Fit bolts securing IRD to gearbox and tighten
sufficiently only to pull mating faces of IRD and
gearbox together at this stage.
5.Fit IRD support brackets, tighten sufficiently to
pull mating faces together.
6.Final tighten bolts securing IRD to gearbox to
90 Nm (66 lbf.ft).
7.Final tighten bolts securing IRD support
brackets in the following sequence:
lM8 bolts securing support brackets to IRD
37 Nm (22 lbf.ft)
lM10 bolts securing support brackets to IRD
50 Nm (22 lbf.ft)
l3 bolts securing support bracket to cylinder
block 25 Nm (18 lbf.ft)
l3 bolts securing support bracket to sump at
45 Nm (33 lbf.ft).
8.Position lower engine steady, 'TOP' mark
uppermost. Fit bolt but do not tighten at this
stage.
9.Connect coolant hoses and secure with clips.
10.Connect breather hose to IRD housing.
11.Clean propeller shaft flange and mating face.
12.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 40 Nm (30
lbf.ft).
13.Inspect drive shaft oil seal, renew if worn or
damaged.14.Clean drive shaft and flange splines.
15.Fit new circlip to drive shaft.
16.With assistance, pull hub outwards, align drive
shaft and fit to IRD taking care not to damage
oil seal.
17.Fit splash shield and secure with bolts.
18.Fit exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - front.
19.Fit rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
20.Final tighten bolt securing lower engine steady
to IRD support bracket to 100 Nm (74 lbf.ft).
21.Remove stand(s) and lower vehicle.
22.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
23.Fill gearbox with fluid.

+ MANUAL GEARBOX - GETRAG,
ADJUSTMENTS, Gearbox oil - drain and
refill.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
24.Connect battery earth lead.
25.Refill cooling system.

+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-7
Intermediate reduction drive (IRD) unit -
K1.8
$% 41.25.01.99
Remove
1.Disconnect battery earth lead.
2.Remove rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
3.Remove exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES 1.8, REPAIRS, Exhaust pipe -
front.
4.Drain fluid from IRD.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
5.Drain gearbox oil.

+ MANUAL GEARBOX - PG1,
ADJUSTMENTS, Gearbox oil - drain and
refill.
6.Remove 3 bolts securing RH splash shield to
body and remove shield.7.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release drive shaft from
IRD.
8.With assistance, pull hub outwards and release
drive shaft from IRD.
CAUTION: Care must be taken not to
damage oil seal when removing drive shaft
from IRD.
9.Remove and discard drive shaft circlip.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-9
24.Remove 3 bolts securing IRD support bracket
to sump and remove bracket.
25.Remove 4 bolts securing IRD.
26.With assistance, release IRD from gearbox and
remove.
27.Remove and discard 'O' ring from IRD.
Refit
1.Clean mating faces of IRD and gearbox.
2.Lubricate and fit new 'O' ring
3.With assistance, fit IRD.
4.Fit bolts securing IRD to gearbox and tighten
sufficiently only to pull mating faces of IRD and
gearbox together at this stage.
5.Fit IRD support bracket and tighten bolts
sufficiently only to pull mating faces together.
6.Final tighten bolts securing IRD to gearbox to
90 Nm (66 lbf.ft).
7.Final tighten bolts securing IRD support bracket
in following sequence:
l5 bolts securing IRD support bracket to IRD
50 Nm (37 lbf.ft)
l1 bolt securing support bracket to cylinder
block to 45 Nm (33 lbf.ft)
l3 bolts securing support bracket to sump 88
Nm (65 lbf.ft).8.Position engine lower steady bracket to sump,
fit and tighten bolts to 100 Nm (74 lbf.ft).
9.Fit engine lower steady, fit bolt securing steady
to gearbox bracket but do not tighten at this
stage.
10.Connect coolant hoses and secure with clips.
11.Connect breather hose to IRD housing.
12.Fit mass damper to pinion housing, fit nuts and
tighten to 25 Nm (18 lbf.ft).
13.Clean propeller shaft flange and mating face.
14.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 40 Nm (30
lbf.ft).
15.Inspect drive shaft oil seal, renew if worn or
damaged.
16.Clean drive shaft and flange splines.
17.Fit new circlip to drive shaft.
18.With assistance, pull hub outwards, align drive
shaft and fit to IRD taking care not to damage
oil seal.
CAUTION: Pull the drive shaft to ensure the
circlip is fully engaged and retains the shaft.
19.Fit splash shield and secure with bolts.
20.Fit exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES 1.8, REPAIRS, Exhaust pipe -
front.
21.Fit rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
22.Final tighten bolt securing lower engine steady
to sump bracket to 80 Nm (59 lbf.ft).
23.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
24.Refill gearbox with oil.

+ MANUAL GEARBOX - PG1,
ADJUSTMENTS, Gearbox oil - drain and
refill.
25.Connect battery earth lead.
26.Refill cooling system.

+ COOLING SYSTEM - K SERIES 1.8,
ADJUSTMENTS, Coolant - refill system.
M12 7167
M41 7698