2001 LAND ROVER FREELANDER engine coolant

ENGINE - K SERIES KV6
OVERHAUL 12-3-91
Cylinder head gasket - RH
$% 12.29.03.01
Remove
1.Remove inlet manifold chamber.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, OVERHAUL, Seals -
manifold chamber - up to 03MY.
2.Remove and discard camshaft timing belt.

+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.
3.Release RH HO2S multiplug from coolant rail
bracket and disconnect multiplug.
4.Using sequence shown, loosen then remove 4
nuts securing RH exhaust manifold to cylinder
head.
5.Remove exhaust manifold, remove and discard
gasket.6.Remove 4 bolts securing RH front timing belt
cover backplate to cylinder head and remove
backplate.
7.Remove RH camshaft cover gasket.

+ ENGINE - K SERIES KV6, REPAIRS,
Camshaft cover gasket - RH.
8. Up to 03MY: Remove 3 nuts and 3 bolts
securing ignition coils to LH inlet manifold and
release coil earth lead.
9. Up to 03MY:Remove ignition coils and position
aside.
M30 0996

ENGINE - K SERIES KV6
12-3-92 OVERHAUL
10.Release clip and disconnect coolant bleed
hose from RH inlet manifold, position hose
aside.
11.Release injector harness clips from injector
protection cover - if fitted, or from bosses on
fuel rail.
12.Remove 2 bolts securing protection cover - if
fitted and RH fuel rail to RH inlet manifold,
remove cover.13.Remove 2 bolts securing fuel rail to LH inlet
manifold.
14.Release injectors from manifolds and carefully
lay fuel rail and injectors aside.
CAUTION: Always fit plugs to open
connections to prevent contamination.
15.Using sequence shown, progressively loosen
and remove 8 cylinder head bolts.
16.Remove cylinder head.
CAUTION: Support both ends of cylinder
head on blocks of wood.
17.Remove and discard cylinder head gasket.
CAUTION: Do not rotate crankshaft with LH
cylinder head fitted.

ENGINE - K SERIES KV6
12-3-94 OVERHAUL
16.Position injector protection cover - if fitted to RH
fuel rail and secure injector harness to
protection cover or fuel rail with clips.
17.Fit bolts securing fuel rail to inlet manifolds and
tighten to 9 Nm (7 lbf.ft).
18.Connect coolant bleed hose to inlet manifold
and secure with clip.
19. Up to 03MY:Position ignition coils to LH inlet
manifold.
20. Up to 03MY:Position earth lead, fit nuts and
bolts securing ignition coils to LH inlet manifold
and tighten to 9 Nm (7 lbf.ft).
21.Clean camshaft timing belt cover backplate
bolts and apply sealant, Part No. STC 50552 to
the first 3 threads.
22.Position backplate, fit and tighten bolts to 9 Nm
(7 lbf.ft).
23.Fit new camshaft timing belt.

+ ENGINE - K SERIES KV6,
OVERHAUL, Camshaft timing belt.
24.Clean exhaust manifold and mating face on
cylinder head.
25.Fit new exhaust manifold gasket. Position
exhaust manifold, fit nuts and using sequence
shown, tighten to 45 Nm (33 lbf.ft).
26.Connect RH HO2S multiplug, secure multiplug
in coolant rail bracket.
Cylinder head - decarbonise
$% 12.29.19
Remove
1.Remove cylinder head gaskets.

+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - LH.

+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - RH.
Disassembly
1. LH Cylinder head: Remove 3 bolts securing
LH rear timing belt cover and remove cover.
2. RH Cylinder head: Remove 2 bolts securing
RH rear timing belt cover heat shield to cylinder
head.
3. RH Cylinder head:Remove 3 bolts securing
RH rear timing belt cover; remove cover.
M12 6880
M12 6694

ENGINE - K SERIES KV6
OVERHAUL 12-3-97
21.Remove valve stem oil seal using LRT-12-071.
Discard stem seal.
22.Repeat procedure for remaining valves,
keeping components in their fitted order.
Inspect
1.Clean camshafts, bearing running surfaces in
carrier and cylinder head, carrier and cylinder
head mating faces.
2.Inspect camshafts and replace camshafts if
scored, pitted or excessively worn.
3.Position camshafts in cylinder head and place
Plastigauge across each journal.
CAUTION: Ensure camshafts are in their
correct fitted locations. Camshafts are
colour coded - Inlet - Orange; Exhaust -
Blue.
4.Refit camshaft carrier, fit bolts and using
sequence shown, tighten to 10 Nm (7.5 lbf.ft).
Do not rotate camshafts.5.Using the sequence shown, progressively
loosen and remove camshaft carrier bolts.
Release and remove camshaft carrier from
cylinder head.
6.Measure widest part of Plastigauge on each
journal.

+ GENERAL DATA, Engine - KV6
Petrol.
7.If clearance is excessive, fit new camshafts and
repeat check. If clearance is still excessive
renew cylinder head.
8.Remove all traces of Plastigauge using an oily
rag.
9.Clean sealing surfaces of cylinder heads.
Clean inlet and exhaust manifold mating faces.
CAUTION: Do not use a metal scraper.
10.Decarbonise combustion areas of cylinder
heads
11.Blow out all oilways and coolant passages.
12.Check cylinder head for damage, pay particular
attention to sealing faces.
M12 6889
LRT-12-071
mm.025.038.051.076
M12 6887

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.

EMISSION CONTROL
REPAIRS 17-1-9
Thermal valve - exhaust gas
recirculation (EGR) - Td4 Automatic
transmission (hot climates) - from 03 MY
$% 17.45.07
Remove
1.Disconnect the battery earth lead.
2.Release thermal valve coolant hose from clips.
3.Position container to collect coolant.
4.Release 3 clips securing coolant hoses to the
EGR thermal valve.
5.Disconnect coolant hoses from the EGR
thermal valve and remove the thermal valve.
Refit
1.Position the EGR thermal valve and connect
coolant hoses.
2.Secure hoses with clips.
3.Fit thermal valve coolant hose into clips.
4.Connect the battery earth lead.
5.Refill the cooling system.

+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.
Cooler - EGR - Td4
$% 17.45.40
Remove
1.Disconnect battery earth lead.
2.Remove camshaft cover.

+ ENGINE - Td4, REPAIRS, Gasket -
camshaft cover.
3.Mark EGR pipe and cooler to aid refit.
4.Loosen clamps EGR pipes to cooler and move
clamps aside.
5.Remove pipe, EGR cooler to EGR valve.
6.Remove bolt securing fuel rails to support
bracket.
7.Remove bolt securing turbocharger outlet pipe
to support bracket.
8.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
M170364

M17 0283

EMISSION CONTROL
17-1-10 REPAIRS
9.Remove bolt securing turbo outlet pipe to upper
coolant rail.
10.Remove 2 bolts securing pipe support bracket
to engine lifting bracket, remove support
bracket.
11.Release clip and remove vacuum hose.
12.Remove 3 bolts securing EGR cooler to
cylinder head and lifting bracket.13.Lift EGR cooler from mounting and position a
container beneath coolant hoses.
14.Release clips and remove hoses from EGR
cooler allow coolant to drain.
15.Remove EGR cooler.
Refit
1.Position EGR cooler, connect coolant hoses
and fit clips.
2.Position EGR cooler to mounting, fit bolts and
tighten to 25 Nm (18 lbf.ft).
3.Position pipe support bracket to engine lifting
bracket, fit and tighten bolts to 25 Nm (18 lbf.ft).
4.Fit vacuum hose and tighten clip.
5.Fit bolt securing turbocharger pipe to coolant
rail and tighten to 25 Nm (18 lbf.ft).
6.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
7.Fit bolt securing turbocharger outlet pipe to
support bracket and tighten to 10 Nm (7.5
lbf.ft).
8.Fit bolt securing fuel rails to support bracket
and tighten to 10 Nm (7.5 lbf.ft).
9.Align EGR pipe to cooler fit clamp, but do not
fully tighten until camshaft cover is refitted.
10.Fit EGR pipe clamp and tighten screw.
11.Fit camshaft cover.

+ ENGINE - Td4, REPAIRS, Gasket -
camshaft cover.
12.Connect battery earth lead.
13.Top up cooling system.

+ MAINTENANCE, MAINTENANCE,
Cooling System and Intercooler.

ENGINE MANAGEMENT SYSTEM - SIEMENS
18-3-8 REPAIRS
Sensor - intake air temperature (IAT) -
NAS
$% 18.30.09
Remove
1.Disconnect multiplug from IAT sensor.
2.Release clip and remove IAT sensor. Discard
seal.
Refit
1.Clean IAT sensor and mating face.
2.Fit new seal to sensor.
3.Fit IAT sensor and connect multiplug.
Sensor - engine coolant temperature
(ECT)
$% 18.30.10
Remove
1.Disconnect battery earth lead.
2.Remove thermostat.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Thermostat.
3.Disconnect multiplug from coolant temperature
sensor.
4.Remove coolant temperature sensor and
discard sealing washer.
5.Remove coolant temperature sensor from
cylinder block.
6.Remove steel shim and sealing washer from
temperature sensor, discard sealing washer.
Refit
1.Clean coolant temperature sensor and mating
face on cylinder block.
2.Fit new sealing washer, then steel shim to
coolant temperature sensor.
3.Position coolant temperature sensor and
tighten to 17 Nm (12.5 lbf.ft).
4.Fit thermostat.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Thermostat.
5.Connect battery earth lead.