2001 LAND ROVER FREELANDER gearbox

ENGINE - K SERIES KV6
12-3-42 REPAIRS
69.Using gearbox bracket bolts, secure LRT-44-
026 lifting bracket to gearbox.
70.Place a wooden block on jack, position jack
under gearbox and raise jack sufficient to
support weight of gearbox. Release lifting hook
from rear engine lifting bracket and connect to
lifting bracket on gearbox.
71.Remove bolt securing upper RH engine steady
to top arm.
72.Loosen bolt securing upper RH engine steady
to body, pivot engine steady away from top
arm.73.Remove bolt securing PAS pipe to engine front
mounting plate.
74.Remove nut and 4 bolts securing engine top
arm bracket to RH hydramount and to engine
front mounting bracket.
75.Release PAS pipe support bracket from
hydramount and position pipe aside.
76.Remove bolt securing PAS pipe to engine front
mounting plate.
77.Remove top arm.
M12 6605

ENGINE - K SERIES KV6
REPAIRS 12-3-43
78.Remove 3 Torx screws securing PAS pump
pulley and remove pulley.
79.Remove 3 bolts securing PAS pump to front
mounting plate and tie pump aside.
80.With assistance, manoeuvre and lower engine
and gearbox to floor.
Refit
1.With assistance, raise engine and gearbox into
engine compartment.
2.Position PAS pump to front mounting plate, fit
and tighten bolts to 25 Nm.
3.Position PAS pump pulley, fit and tighten Torx
screws to 9 Nm.
4.Position top arm to engine mounting bracket
and RH hydramount, fit and tighten bolts to 100
Nm.
5.Position PAS pipe support bracket to RH
hydramount, fit and tighten nut to 85 Nm.
6.Place a wooden block on jack, position jack
under gearbox and raise jack sufficient to
support weight of gearbox. Release lifting hook
from lifting bracket on gearbox and connect to
rear engine lifting bracket.
7.Lower and remove jack supporting gearbox.8.Remove bolts securing 44-026 lifting bracket to
gearbox and remove bracket.
9.Position LH mounting bracket to gearbox, fit
and tighten bolts to 85 Nm.
10.Position LH mounting to body, fit and tighten
bolts to 48 Nm.
11.Align gearbox bracket to LH body mounting, fit
and tighten through bolt to 100 Nm.
12.Position upper RH engine steady to top arm, fit
and tighten bolt to 100 Nm.
13.Tighten bolt securing upper RH engine steady
to body to 100 Nm.
14.Position PAS pipe to engine front mounting
plate, fit and tighten bolt to 25 Nm.
15.Lower hoist, disconnect and remove lifting
bracket, LRT-12-138.
16.Raise vehicle on lift.
17.Position A/C compressor to front mounting
plate and cylinder block, align heat shield, fit
and tighten bolts to 25 Nm.
18.Connect multiplug to A/C compressor.
19.Using a 3/8" square drive socket bar, raise
ancillary drive belt tensioner and fit drive belt to
pulleys.
20.Position selector cable to gearbox bracket and
secure with clip.
21.Position selector lever to selector shaft, fit and
tighten nut to 25 Nm.
22.Clean splines and seal areas on each drive
shaft and mating faces in front hubs.
23.Fit new circlips to RH and LH drive shaft inner
joint splines.
24.Fit drive shafts to IRD and gearbox, ensuring
that the circlip on each drive shaft is fully
engaged.
25.Engage LH and RH drive shafts into front hubs.
26.Fit new drive shaft flange nuts but do not tighten
at this stage.
27.Clean ball joint tapers and taper seats.
28.Position LH and RH track rod ends to steering
arms, fit new nuts and tighten to 55 Nm.
29.Clean ABS sensors and mating faces.
30.Apply anti-seize grease to both ABS sensors
and position sensors in front hubs.
CAUTION: Ensure ABS sensor is fully
located into hub, so that sensor touches
pole wheel teeth.
31.Position LH and RH brake hoses to front
damper brackets and secure with clips.
32.Position LH and RH splash shields, fit and
tighten bolts.
33.Ensure mating face of propeller shaft and IRD
drive flange are clean.
34.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 42 Nm (31
lbf.ft).

ENGINE - K SERIES KV6
12-3-44 REPAIRS
35.Fit rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
36.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
37.Fit exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - NAS.
38.With assistant depressing the brake pedal,
tighten front hub nuts to 400 Nm.
39.Stake nuts to drive shafts
40.Fit front road wheels, fit and tighten nuts to 115
Nm.
41.Lower vehicle on lift.
42.Connect brake servo vacuum hose to inlet
manifold chamber.
43.Connect coolant hose to underside of
expansion tank and secure with clip.
44.Connect expansion tank hose to inlet manifold
and secure clip.
45.Connect top hose to radiator and secure with
clip. Position hose in bracket.
46.Connect heater feed and return hoses and
secure with clips.
47.Connect throttle inner cable to throttle cam and
secure outer cable in abutment bracket.
48.Connect hose to purge valve.
49.Fit purge hose into clip.
50.Connect fuel hose to fuel rail pipe, fit rubber
sleeve over hose connector.
51.Connect gearbox harness multiplugs and
secure multiplugs in mounting bracket clips.
52.Connect Lucar connector to starter solenoid.
53.Position earth lead to gearbox housing, fit and
tighten bolt to 25 Nm.
54.Position engine harness to 'E' box mounting
bracket and secure with clips.
55.Connect earth header multiplug.
56.Connect multiplug to under bonnet fuse box.
57.Position battery and starter motor lead to under
bonnet fuse box, fit and tighten bolts to 8 Nm.
58.Fit under bonnet fuse box cover.
59.Position 'E' box, secure in retaining clip, fit and
tighten nut to 9 Nm.
60.Fit carrier to 'E' box.
61.Fit air ducting to 'E' box.
62.Fit body harness to 'E' box, secure grommet
and harness clip.
63.Connect 'E' box cooling fan multiplug.
64.Connect multiplug to 'E' box temperature
sensor.
65.Connect multiplug to gearbox ECU.
66.Position engine harness to 'E' box and secure
grommet.67.Fit engine harness clamp and secure with
screws.
68.Connect engine harness multiplug to body
harness multiplug and fit multiplug to 'E' box.
69.Fit heated front screen harness to battery
positive cable and tighten bolt to 15 Nm (11
lbf.ft).
70.Fit engine ECM.

+ ENGINE MANAGEMENT SYSTEM -
SIEMENS, REPAIRS, Engine control module
(ECM) - fuel - NAS.
71.Fit battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
72.Fill cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
73.Connect the battery earth lead.
74.Fill gearbox with fluid.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
75.Fit the engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
76.Untie and close bonnet.

ENGINE - K SERIES KV6
12-3-46 REPAIRS
Engine mounting - LH
$% 12.45.11
Remove
1.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
2.Remove battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
3.Using a hoist, connect adjustable lifting
bracket, LRT-12-138 to engine.
4.Raise hoist to take weight without exerting any
load on the engine mountings.
5.Remove through bolt securing LH engine
mounting to gearbox bracket.
6.Remove 4 bolts securing LH mounting to body
and remove mounting.Refit
1.Position LH mounting to body, fit and tighten
bolts to 48 Nm (35 lbf.ft).
2.Align gearbox bracket to LH body mounting, fit
and tighten through bolt to 100 Nm (74 lbf.ft).
3.Lower hoist, disconnect and remove lifting
bracket, LRT-12-138.
4.Fit battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
5.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
M12 6599

ENGINE - K SERIES KV6
REPAIRS 12-3-49
Torque converter drive plate
$% 12.53.13
Remove
1.Remove automatic gearbox.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gearbox - KV6.
2.Assemble LRT-12-161 to LRT-12-199 and
secure with clamp bolt.
3.Position LRT-12-161 and LRT-12-199 to
crankshaft pulley to restrain crankshaft.
4.Remove and discard 6 Patchlok bolts securing
drive plate to crankshaft.
5.Remove drive plate from crankshaft.Refit
1.Clean bolt holes in crankshaft using an old
drive plate bolt with two saw cuts at an angle of
45° to the bolt shank.
2.Clean drive plate and mating face of
crankshaft.
3.Position LRT-12-161 and LRT-12-199 to
crankshaft pulley to restrain crankshaft.
4.Position drive plate to crankshaft.
5.Fit new Patchlok bolts securing drive plate to
crankshaft and tighten in sequence shown to:
lStage 1 - 25 Nm (18 lbf.ft)
lStage 2 - 100 Nm (74 lbf.ft)
6.Remove LRT-12-161 and LRT-12-199 from
crankshaft pulley.
7.Fit automatic gearbox.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gearbox - KV6.

ENGINE - K SERIES KV6
OVERHAUL 12-3-81
Crankshaft rear oil seal
$% 12.21.20.01
Remove
1.Remove automatic gearbox.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gearbox - KV6 - with engine and
gearbox removed.
2.Assemble LRT-12-161 to LRT-12-199 and
secure with clamp bolt.
3.Position LRT-12-161 and LRT-12-199 to
crankshaft pulley to restrain crankshaft.
4.With assistance, remove and discard 6 bolts
securing drive plate to crankshaft.
5.Remove drive plate from crankshaft.6.Remove and discard 5 bolts securing
crankshaft rear oil seal housing to cylinder
block.
7.Remove crankshaft rear oil seal.
Refit
1.Clean cylinder block face and oil seal running
surface on crankshaft, ensure bolt holes are
clean and dry.
2.Position oil seal protector, LRT-12-061 to
crankshaft.
3.Position oil seal to crankshaft.
CAUTION: Oil seal must be fitted dry.

ENGINE - K SERIES KV6
12-3-82 OVERHAUL
4.Fit new Patchlok bolts securing oil seal to
cylinder block and using sequence shown,
tighten to 8 Nm (6 lbf.ft).
5.Remove oil seal protector LRT-12-061.
6.Clean bolt holes in crankshaft using an old
drive plate bolt with two saw cuts at an angle of
45° to the bolt shank.
7.Clean drive plate and mating face of
crankshaft.
8.Position drive plate to crankshaft and fit but do
not tighten new Patchlok bolts.
9.Position LRT-12-161 and LRT-12-199 to
crankshaft pulley to restrain crankshaft.
10.Using sequence shown, tighten to bolts to:
lStage 1 - 25 Nm (18 lbf.ft)
lStage 2 - 100 Nm (74 lbf.ft)
11.Remove special tool from crankshaft pulley,
loosen bolt and remove LRT-12-161 from LRT-
12-199.
12.Fit automatic gearbox.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gearbox - KV6 - with engine and
gearbox removed.
Crankshaft
$% 12.21.33.01
Remove
1.Remove cylinder head gaskets.

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

+ ENGINE - K SERIES KV6,
OVERHAUL, Cylinder head gasket - RH.
2.Remove oil pump gasket.

+ ENGINE - K SERIES KV6,
OVERHAUL, Oil pump - Overhaul.
3.Remove crankshaft rear oil seal.

+ ENGINE - K SERIES KV6,
OVERHAUL, Crankshaft rear oil seal.
4.Remove engine sump.

+ ENGINE - K SERIES KV6,
OVERHAUL, Sump - engine oil.
Disassembly
1.Remove bolt securing oil pick up strainer,
remove strainer and discard 'O' ring.

ENGINE MANAGEMENT SYSTEM - SIEMENS
REPAIRS 18-3-9
Sensor - crankshaft position (CKP)
$% 18.30.12
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Disconnect CKP sensor multiplug from engine
harness.
4.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Remove bolt securing CKP sensor to gearbox
housing and remove sensor.Refit
1.Clean CKP sensor and mating face.
2.Position CKP sensor, fit and tighten bolt to 9
Nm (6.5 lbf.ft).
3.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
4.Connect CKP sensor multiplug to engine
harness.
5.Fit engine acoustic cover.

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