2001 LAND ROVER FREELANDER check oil

FUEL DELIVERY SYSTEM - PETROL
19-2-40 REPAIRS
Refit
1.Remove protective caps from each injector.
2.Clean injectors and recesses in fuel rail and
inlet manifold.
3.Lubricate new 'O' ring with castor oil and fit to
injector.
4.Fit injectors to fuel rail and secure with spring
clips.
5.Position fuel rail assembly and connect injector
multiplugs.
6.Fit injector spacer.
7.Push each injector into inlet manifold.
8.Fit bolts securing fuel rail to inlet manifold and
tighten to 8 Nm ( 6 lbf.ft).
9.Connect fuel feed hose to fuel rail.
10.Fit engine oil dipstick.
11.Connect vacuum pipe to fuel pressure regulator
and secure with clip.
12.Connect battery earth lead.
Actuator unit - cruise control - KV6 - non
NAS
$% 19.75.05
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Disconnect vacuum hose from actuator.
4.Remove nut securing actuator to mounting
bracket.
5.Release operating rod from throttle cam and
remove actuator.
Refit
1.Position actuator and connect operating rod to
throttle cam.
2.Position actuator into mounting bracket, fit and
tighten nut.
3.Connect vacuum hose to actuator.
4.Check pull rod to retainer clearance, with lever
fully returned, pull rod should just be held by
retainer.
5.Release retainer by turning anti-clockwise,
eliminate clearance then rotate retainer half
turn clockwise. Check pull rod is just held and
rotate retainer a further quarter turn clockwise
to lock.
6.Fit engine acoustic cover.

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

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-17
30.Remove and discard seals from inlet manifold
chamber and 'O' rings from RH inlet manifold.Refit
1.Clean seal faces on inlet manifold chamber and
inlet manifolds.
2.Fit new 'O' rings to RH inlet manifold and new
seals to manifold chamber.
3.Position inlet manifold chamber, secure RH coil
harness clips in inlet manifold chamber support
brackets.
4.Connect multiplugs to plug top coils and secure
with locking clips.
5.Align inlet manifold chamber to inlet manifolds,
fit and tighten bolts to 18 Nm (13 lbf.ft).
6.Align inlet manifold chamber support brackets
to RH camshaft cover, fit and tighten bolts to 10
Nm (7.5 lbf.ft).
7.Position engine harness brackets to inlet
manifold chamber, fit and tighten screws.
8.Connect multiplugs to VIS motors.
9. NAS models: Connect engine breather pipe.
10. NAS models: Connect multiplugs to IAT and
MAF sensors.
11.Connect brake servo vacuum hose to inlet
manifold chamber.
12.Connect vacuum/breather hoses to LH and RH
camshaft covers and to throttle body.
13.Connect cruise control actuator vacuum pipe.
14. Non NAS models: Connect vacuum hose to
IACV housing.
15. Non NAS models: Connect multiplugs to TP
and IACV sensors.
16.Connect vacuum/breather hoses to LH
camshaft cover, 'T' piece and purge control
valve.
17. Non NAS models: Connect small vacuum
hose to purge control valve.
18.Connect multiplug to purge control valve .
19.Connect EVAP hose to purge control valve.
20.Connect fuel hose to fuel rail pipe, fit rubber
sleeve over hose connector.
21.Remove absorbent cloth.
22. Non NAS models: Connect throttle inner cable
to throttle cam and secure outer cable in
abutment bracket.
23. Non NAS models: Secure throttle cable in
clips on harness brackets.
24.Adjust throttle cable, if fitted.

+ FUEL DELIVERY SYSTEM -
PETROL, ADJUSTMENTS, Throttle cable -
check and adjust - KV6.
25.Remove vacuum enhancer.

+ BRAKES, REPAIRS, Vacuum -
enhancer - KV6.
26.Connect battery earth lead.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-22 REPAIRS
Refit
1.Clean seal faces on inlet manifold chamber and
inlet manifolds.
2.Fit new 'O' rings to RH inlet manifold and new
seals to inlet manifold chamber.
3.Position inlet manifold chamber, secure RH coil
harness clips in inlet manifold chamber support
brackets.
4.Align inlet manifold chamber to inlet manifolds,
fit and tighten bolts to 18 Nm (13 lbf.ft).
5.Align inlet manifold chamber support brackets
to RH camshaft cover, fit and tighten bolts to 10
Nm (7 lbf.ft).
6.Connect multiplugs to plug top coils and secure
with locking clips.
7.Position engine harness brackets to inlet
manifold chamber, fit and tighten screws.
8.Connect multiplugs to VIS motors.
9. NAS models: Align harness and fuel feed pipe.
Secure harness and pipe in clip on manifold
chamber.
10. NAS models: Using a new clip, fit intake hose
to throttle body and secure hose with clip.
11. NAS models: Connect multiplug to throttle
body.
12. NAS models: Connect multiplugs to IAT and
MAF sensors.
13. NAS models: Fit vacuum/breather pipe and
connect to LH camshaft cover, RH camshaft
cover link pipe and inlet manifold chamber.
14. NAS models: Using a new clip, fit vacuum/
breather pipe to engine air intake hose and
secure pipe with clip.
15. NAS models: Connect vacuum/breather pipe
to LH and RH camshaft covers. Fit pipe into
clip.16. Non NAS models: Connect cruise control
actuator vacuum pipe.
17. Non NAS models: Fit vacuum/breather pipe to
throttle body and connect pipe to LH and RH
camshaft covers.
18. Non NAS models: Fit vacuum/breather pipe to
purge control valve and LH camshaft cover.
Using a new clip, connect pipe to 'T' piece and
secure pipe with clip.
19. Non NAS models: Connect multiplug to TP
sensor.
20. Non NAS models: Connect multiplug to IACV.
21. Non NAS models: Connect vacuum pipe to
IACV.
22. Non NAS models: Connect small vacuum pipe
to purge control valve.
23.Connect multiplug to purge control valve .
24.Connect EVAP hose to purge control valve.
25.Connect fuel hose to fuel rail pipe, fit rubber
sleeve over hose connector.
26. Non NAS models: Connect throttle inner cable
to throttle cam and secure outer cable in
abutment bracket.
27. Non NAS models: Secure throttle cable in
clips on harness brackets.
28. Non NAS models: Adjust throttle cable.

+ FUEL DELIVERY SYSTEM -
PETROL, ADJUSTMENTS, Throttle cable -
check and adjust - KV6.
29.Fit vacuum enhancer.

+ BRAKES, REPAIRS, Vacuum -
enhancer - KV6.
30.Connect the battery earth lead.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-21
12.Using flanged end of LRT-41-015 fit outer seal
to depth dictated by tool flange.
CAUTION: Use end protector of LRT-41-015
to avoid damage to the working surfaces of
the tool.
13.Remove oil seal protector.
14.Fit IRD.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - K1.8.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - Td4.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.
Seal - pinion gear
$% 41.29.04
Remove
1.Remove pinion housing.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - Td4.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - K1.8.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - KV6 - Non NAS.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - KV6 - NAS.
CAUTION: Before dismantling the pinion
housing, measure the turning torque on
existing bearings.
2.Attach pinion housing to suitable mounting
plate and secure mounting plate in vice.
3.Check pinion torque to turn figure.
4.Reference mark pinion flange and pinion shaft
for assembly purposes.
5.Restrain pinion flange using LRT-51-003.
6.Remove and discard nut.
7.Position pinion housing onto press, fit suitable
adaptor on end of pinion shaft, press pinion
shaft from drive flange and housing.
8.Remove and discard collapsible spacer.
9.Using a suitable lever, remove pinion oil seal.
CAUTION: Take care to avoid damage to oil
seal recess.
10.Remove pinion bearing inner race.

INTERMEDIATE REDUCTION DRIVE
41-22 REPAIRS
Refit
1.Clean pinion shaft, drive flange and housing.
2.Clean oil seal recess.
3.Lubricate and fit bearing to pinion housing.
4.Lubricate new seal.
5.Using a suitable adapter, press seal into
housing.
CAUTION: Oil seal must be flush with end of
pinion housing.
6.Assemble pinion to housing using new
collapsible spacer.
7.Lightly lubricate drive flange splines with
Molybdenum Disulphide grease.
8.Align pinion to drive flange reference marks
and press flange onto pinion shaft until a 2 mm
clearance exists in bearings.
9.Fit pinion assembly to mounting plate and
secure in vice.
10.Fit new pinion nut, hold pinion drive flange
using LRT-51-003 and tighten pinion nut to 150
Nm (111 lbf.ft).
11.Check pinion torque to turn figure.
NOTE: Figure for new bearings is 180 to 200
Ncm.
If original bearing figure is above 20 to 30 Ncm
and below new bearing figure, set to figure
recorded.
If original bearing is below 20 Ncm set to 20 to
30 Ncm.12.If turning torque is too low, carefully tighten nut
and recheck reading. If turning torque is too
high, pinion assembly will have to be
dismantled and a new collapsible spacer fitted.
Reassemble using new nut and recheck turning
torque.
13.Check drive flange run-out using a Dial Test
Indicator (DTI).
CAUTION: The drive flange run-out should
not exceed 0.05 mm.
14.Remove pinion housing from vice and
mounting plate.
15.Fit pinion housing.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - Td4.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - K1.8.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - KV6 - Non NAS.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - KV6 - NAS.

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-11
Oil seal - torque converter
$% 44.17.11
Remove
1.Remove gearbox assembly.

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

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gearbox - Td4.
2.Remove torque converter from gearbox.
Discard 'O' ring from gearbox input shaft.
3.Remove torque converter oil seal from
gearbox. Discard torque converter oil seal.
CAUTION: When removing torque converter
oil seal take care not to damage oil pump
housing.Refit
1.Clean torque converter spigot.
2.Clean torque converter oil seal recess in
gearbox. Lubricate torque converter oil seal
with clean transmission fluid.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
3.Fit new torque converter oil seal using LRT-44-
024.
4.Lubricate and fit new 'O' ring to input shaft.
5.Fit torque converter.
6.Ensure converter is fully located in oil pump
drive by checking depth 'A' as illustrated.
lKV6 models: Depth A = 4 mm.
lTd4 models: Depth A = 27 mm.
7.Fit gearbox assembly.

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

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gearbox - Td4.
M44 1659
A

AUTOMATIC GEARBOX - JATCO
44-16 REPAIRS
35.Remove 2 top bolts securing gearbox to
engine.
36.Release gearbox from 2 dowels.
37.Remove gearbox assembly.
38.Fit converter retaining plate and secure with
bolts.Refit
1.Remove torque converter retaining plate.
2.Ensure converter is fully located in oil pump
drive by checking depth 'A' as illustrated. Depth
A = 4 mm.
3.Clean gearbox to engine mating faces, dowels
and dowel holes.
4.Fit gearbox assembly.
5.Fit bolts securing gearbox and tighten to 85 Nm
(63 lbf.ft).
6.Disconnect lifting equipment.
7.Clean CKP sensor and mating face.
8.Fit CKP sensor, fit bolt and tighten to 9 Nm (7
lbf.ft).
9.Position fluid cooler, tighten M12 bolts to 85 Nm
(63 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).
10.Connect hoses to fluid cooler.
11.Clean fluid cooler unions.
12.Lubricate new 'O' rings with clean transmission
fluid and fit 'O' rings to fluid cooler hoses.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
13.Connect fluid cooler hoses to gearbox and
tighten unions to 18 Nm (13 lbf.ft).
14.Clean starter motor mating faces.
15.Position starter motor to gearbox, align CKP
sensor multiplug bracket, fit and tighten bolts to
45 Nm (33 lbf.ft).
16.Using gearbox bracket bolts, secure LRT-44-
026 lifting bracket to gearbox.
17.Position IRD cooling hose retainer, fit bolt and
tighten to 25 Nm (18 lbf.ft).
18.Align marks on drive plate to torque converter.
19.Fit bolts securing drive plate to torque converter
and tighten bolts to 45 Nm (33 lbf.ft).
20.Clean torque converter access plate.
M44 1689
A
M44 1668

AUTOMATIC GEARBOX - JATCO
44-22 REPAIRS
42.Remove 2 top bolts securing gearbox to
engine.
43.Release gearbox from 2 dowels.
44.Manoeuvre and lower gearbox to floor.
45.Fit converter retaining plate and secure with
bolts.Refit
1.Remove torque converter retaining plate.
2.Ensure converter is fully located in oil pump
drive by checking depth 'A' as illustrated. Depth
A = 4 mm.
3.Clean gearbox to engine mating faces, dowels
and dowel holes.
4.Fit gearbox assembly.
5.Fit bolts securing gearbox and tighten to 85 Nm
(63 lbf.ft).
6.Position LH mounting bracket to gearbox, fit
and tighten bolts to 85 Nm (63 lbf.ft).
7.Position LH mounting to body, fit and tighten
bolts to 48 Nm (35 lbf.ft).
8.Align gearbox bracket to LH body mounting, fit
and tighten through bolt to 100 Nm (74 lbf.ft).
9.Disconnect lifting equipment.
10.Remove nuts and bolts securing lifting brackets
to gearbox and remove brackets.
11.Connect engine and gearbox harness
multiplugs to main harness.
12.Secure multiplugs to clips.
13.Position engine earth lead and secure with bolt.
14.Fit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - KV6.
15.Clean throttle housing and manifold chamber
mating faces.
16.Fit new seal to inlet manifold chamber.
17.Position throttle housing to manifold chamber,
fit Torx screws and tighten to 7 Nm (7 lbf.ft).
18.Connect throttle inner cable to throttle cam and
secure outer cable in abutment bracket, if fitted.
19.Connect hose to cruise control actuator.
20.Secure breather hoses to throttle housing, if
fitted.
21.Adjust throttle cable, if fitted.

+ FUEL DELIVERY SYSTEM -
PETROL, ADJUSTMENTS, Throttle cable -
check and adjust - KV6.
22.Clean CKP sensor and mating face.
M44 1689
A
M44 1668