2001 LAND ROVER FREELANDER service

ENGINE - K SERIES KV6
OVERHAUL 12-3-99
20.Insert each valve into its respective guide.
21.Extend valve head 15 mm (0.6 in) out of guide
and position DTI gauge to rear of valve head.
22.Move valve towards front of cylinder head and
zero gauge ensuring that stylus of gauge
remains in contact with valve head.
23.Move valve towards rear of cylinder head,
record gauge reading obtained to give valve
stem to guide clearance 'B'.

+ GENERAL DATA, Engine - KV6
Petrol.
24.Remove valves ensuring they are retained in
their fitted order.
25.Renew valves and/or guides as necessary.
26.To replace valve guides support cylinder head
face down on wooden blocks.
27.Position LRT-12-519-3 in tappet bore and drift
out valve guide using LRT-12-519-1.
CAUTION: Retain guides in their fitted
order.28.Identify type of valve guide fitted: 'A' - Standard
production 'B' - Service replacement.
CAUTION: Standard production valve
guides A must be replaced with service
replacement guides B.
29.Locate valve guide in valve guide bore with
identification groove towards valve seat and
position depth gauge LRT-12-519-2 onto valve
guide.
CAUTION: Cylinder head and valve guides
must be at room temperature when fitting
guides.
30.Position nylon guide LRT-12-519-3 in cylinder
head, press guide into bore using driver LRT-
12-519-1 until depth gauge contacts cylinder
head.
M12 6890
LRT-12-519-1
LRT-12-519-3
M12 6892
LRT-12-519-2
LRT-12-519-1
LRT-12-519-3

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

EMISSION CONTROL
ADJUSTMENTS 17-1-1
EMISS ION CONTROL ADJUST ME NTS
Evaporative loss control system
(EVAPS) - leak test - NAS
$% 17.90.02.01
The following procedure allows a fuel leak, indicated
by the Malfunction Indicator Lamp (MIL), to be
accurately located. It must only be carried out once it
has been established that there are no obvious faults
with any of the system components.
Check
1.Check components in fuel and EVAP system
for obvious damage. Ensure all connections
are properly secured.
2.The system must be checked using a EVAPS
Diagnostic Testing Station LRA-19-004.
3.Disconnect vent pipe from purge valve and
connect adapter LRA-19-004/1.
NOTE: The reason for inserting the adapter into
the purge valve is that there is currently no
service port fitted to Freelander.
4.Remove RH rear wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
5.Release clip and disconnect hose from
charcoal canister.
CAUTION: Before disconnecting any part of
the fuel system, it is imperative that all dust,
dirt and debris is removed from around
components to prevent ingress of foreign
matter into fuel system.
6.Block charcoal canister port with bung,
included in LRA-19-004.
7.Connect LRA-19-004 to service port fitted on
purge valve.
8.Carry out procedures given in the operating
instructions, these are supplied with LRA-19-
004.Adjust
1.If a leak has been detected, replace component
as necessary and repeat leak test to validate
repair.
2.Remove bung from charcoal canister.
3.Connect hose to charcoal canister and secure
with clip.
4.Fit rear wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
5.Disconnect adaptor LRA-19-004/1 from purge
valve.
6.Connect hose to purge valve.

BRAKES
70-4 REPAIRS
Refit
1.Renew brake drum if scored, grooved or
cracked.
2.Check wheel cylinder pistons for freedom of
movement.
3.Clean backplate and brake drum with brake
cleaning fluid.
WARNING: Do not use petroleum based
fluid as damage will occur to rubber
components
4.Measure inside diameter of drum at 2 points.
Drum internal diameter: New = 254 mm.
Service limit: = 255.49 mm. Drum ovality limit:
= 0.012 mm. Renew drum if outside limits.
5.Examine wheel cylinder dust seals for signs of
brake fluid leakage, a certain amount of
dampness is usual. However, if excessive fluid
is apparent, lift dust seals and check for
leakage. Renew wheel cylinders and brake
shoes if linings are contaminated.
6.Apply molykote 111 grease to brake shoe and
spring contact points.
WARNING: Ensure grease does not contact
brake shoe linings or wheel cylinder dust
covers.
Check adjuster ratchet and if necessary set to
minimum adjustment position as follows: Lever
leading shoe away from wheel cylinder; Move
adjuster ratchet back fully; Ease shoe back into
position.7.Fit brake drum and tighten screws.
8.If necessary, fit backplate grommet.
9.Apply brake pedal a min. of 30 times to ensure
full adjustment of rear brake shoes after
refitting.
10.Check handbrake operation, adjust if
necessary.
11.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
12.Remove stands and lower vehicle.

RESTRAINT SYSTEMS
REPAIRS 75-19
Rotary coupler - (SRS) air bag system
$% 76.74.20
Remove
WARNING: It is imperative that before any
work is undertaken on the SRS system the
appropriate information is read thoroughly.
1.Make the SRS system safe.

+ GENERAL INFORMATION,
Supplementary restraint system
precautions.
CAUTION: Before disconnecting any part of
the steering linkage, ensure the road wheels
are positioned straight ahead and the
steering wheel is prevented from turning.
Unrestricted turning of the steering wheel
will damage the SRS rotary coupler.
2.Remove steering wheel.

+ STEERING, REPAIRS, Steering
wheel.
CAUTION: Use adhesive tape to prevent
rotation of the rotary coupler once the
steering wheel is removed.
3.Remove steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
column.
4.Disconnect 2 multiplugs from rotary coupler.
5.Remove 4 screws and remove rotary coupler.
CAUTION: Do not dismantle the rotary
coupler, it has no serviceable parts and
must be replaced as a complete assembly.Refit
1.Ensure the rotary coupler is installed in its
centred position. To obtain centre position,
rotate coupler gently clockwise and
anticlockwise until the white segment appears
on the indicator wheel.
CAUTION: Ensure front road wheels are in
the straight ahead position.
2.Fit rotary coupler and secure with screws.
3.Connect multiplugs to rotary coupler.
4.Fit steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
column.
5.Fit steering wheel.

+ STEERING, REPAIRS, Steering
wheel.
6.Connect battery leads, earth lead last.

PANEL REPAIRS
REPLACEMENT PANELS 77-2-3
REPLACE ME NT PA NELS
Serviceable Panels
Front end panels
1Bonnet locking platform
2LH headlamp mounting panel
3Front lower crossmember assembly
4LH crossmember gusset plate
5RH crossmember gusset plate
6Front bulkhead assembly
7RH headlamp mounting panel
8Bonnet locking platform reinforcement

BODY SEALING MATERIALS
77-3-6 APPLICATION EQUIPMENT
Cooper Pegler Falcon Junior Pneumatic Gun (Airless)
Intended primarily for applying transit wax, this pneumatic sprayer has a 5-litre container with integral hand pump and
provides an effective means of wax spraying without the need for compressed air or additional services.
A selection of nozzles, lances, hose lengths and a trigger valve assembly with integral filter allows flexibility in use.
Additional applications include general maintenance, wax injection and paint application. Heavy-bodied materials
may also be applied. All parts are fully replaceable and a wide range of nozzle configurations is available.
SATA Schutz Gun Model UBE
The SATA Schutz Gun is approved for the retreatment of vehicle underbody areas with protective coatings as
supplied in 1 litre, purpose-designed 'one-way' containers. The screw thread fitting (female on the gun) is standard
to most Schutz-type packs.
Full operating details are supplied with the equipment.
SATA HKD1 Wax Injection Injection Equipment
This equipment is approved for carrying out cavity wax re-treatment. The SATA HKD1 set comprises a high quality
forged gun with 1-litre pressure feed container, a flexible nylon lance, a straight 1100mm steel lance and hooked-
wand lance. A quick-change coupling is provided as a standard fitting to allow lances to be easily interchanged. Each
lance has an integral, machined nozzle with specialised spray characteristics to suit the type of box section to be
treated.

CORROSION PREVENTION AND SEALING
SEALING 77-4-9
Inspections during maintenance servicing
It is a requirement of the Corrosion Warranty that the vehicle body is checked for corrosion by an authorised Land
Rover Dealer at least once a year, to ensure that the factory-applied protection remains effective.
Service Job Sheets include the following operations to check bodywork for corrosion:
lWith the vehicle on a lift, carry out visual check of underbody sealer for damage.
lWith the vehicle lowered, inspect exterior paintwork for damage and body panels for corrosion.
The vehicle must be washed and free from deposits prior to inspection. It is part of the owner's responsibility to ensure
that the vehicle is kept free of accumulations of mud which could accelerate the onset of corrosion. It will be necessary
for the vehicle to be washed by the Dealer prior to inspection of bodywork if the customer has offered the vehicle in
a dirty condition. Particular attention should be paid to areas where access is difficult.
The checks described above are intended to be visual only. It is not intended that the operator should remove trim
panels, finishers, rubbing strips or sound-deadening materials when checking the vehicle for corrosion and paint
damage.
With the vehicle on a lift, and using an inspection or spot lamp, visually check for the following:
lCorrosion damage and damaged paintwork, condition of underbody sealer on front and rear lower panels, sills
and wheel arches.
lDamage to underbody sealer. Corrosion in areas adjacent to suspension mountings and fuel tank fixings.
The presence of small blisters in underbody sealer is acceptable, providing they do not expose bare metal.
Pay special attention to signs of damage caused to panels or corrosion protection material by incorrect jack
positioning.
caut : It is essential to follow the correct jacking and lifting procedures.
With the vehicle lowered, visually check for evidence of damage and corrosion on all visible painted areas, in
particular the following:
lFront edge of bonnet.
lVisible flanges in engine compartment.
lLower body and door panels.
Rectify any bodywork damage or evidence of corrosion found during inspection as soon as is practicable, both to
minimise the extent of the damage and to ensure the long term effectiveness of the factory-applied corrosion
prevention treatment. Where the cost of rectification work is the owner's responsibility, the Dealer must advise the
owner and endorse the relevant documentation accordingly.
Where corrosion has become evident and is emanating from beneath a removable component (e.g. trim panel,
window glass, seat etc.), remove the component as required to permit effective rectification.