2001 LAND ROVER FREELANDER coolant

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-9
Gasket - exhaust manifold - RH - Non
NAS
$% 30.15.16
Remove
1.Disconnect battery earth lead.
2.Release RH HO2S multiplug from coolant rail
bracket and disconnect multiplug.
3.Remove bolt securing upper RH engine steady
to top arm.
4.Loosen bolt securing upper RH engine steady
to body, pivot engine steady away from top
arm.
5.Raise vehicle on a ramp.
6.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
7.Remove exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - Non
NAS.8.Remove bolt securing lower engine steady to
sump mounting bracket.
9.Loosen bolt securing lower engine steady to
subframe, pivot steady away from sump
mounting bracket.
10.Remove cable tie and release gear selector
cable from clip on body.
11.Remove 2 bolts securing IRD heat shield to
lower engine steady mounting bracket.
12.Remove nut securing heat shield to IRD pinion
housing.
13.Remove nut securing heat shield to IRD
housing and remove heat shield.
M30 0996
M12 6597

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-10 REPAIRS
14.Remove 4 nuts securing RH exhaust manifold
to cylinder head.
15.Remove exhaust manifold, remove and discard
gasket.
Refit
1.Clean exhaust manifold and mating face on
cylinder head.
2.Fit new exhaust manifold gasket, position
exhaust manifold, fit nuts and tighten to 45 Nm
(33 lbf.ft).
3.Position heat shield to IRD unit.
4.Fit nut securing heat shield to IRD housing and
tighten to 45 Nm (33 lbf.ft).
5.Fit nut securing heat shield to IRD pinion
housing and tighten to 25 Nm (18 lbf.ft).
6.Fit 2 bolts securing heat shield to lower engine
steady mounting bracket and tighten to 9 Nm (7
lbf.ft).
7.Fit gear selector cable in body clip and secure
with cable tie.
8.Position lower engine steady to sump
mounting, fit and tighten bolt to 100 Nm (74
lbf.ft).
9.Tighten bolt securing lower engine steady to
subframe to 100 Nm (74 lbf.ft).
10.Fit exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - Non
NAS.
11.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
12.Lower vehicle on ramp.
13.Connect RH HO2S multiplug, secure multiplug
in coolant rail bracket.
14.Position upper RH engine steady to top arm, fit
and tighten bolt to 100 Nm (74 lbf.ft).
15.Tighten bolt securing upper RH engine steady
to body to 100 Nm (74 lbf.ft).
16.Connect battery earth lead.
Gasket(s) - exhaust manifold - RH - KV6 -
NAS
$% 30.15.16
Remove
1.Disconnect battery earth lead.
2.Remove RH catalytic converter.

+ EMISSION CONTROL, REPAIRS,
Catalytic converter - RH - KV6 - NAS.
3.Remove 4 nuts securing exhaust manifold to
cylinder head, remove manifold and discard
gasket.
Refit
1.Clean exhaust manifold and mating face.
2.Using new gasket, fit exhaust manifold and
tighten nuts to 45 Nm (33 lbf.ft).
3.Fit RH catalytic converter.

+ EMISSION CONTROL, REPAIRS,
Catalytic converter - RH - KV6 - NAS.
4.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
41-4 REPAIRS
13.Remove 6 nuts and bolts securing propeller
shaft to IRD drive flange.
14.Release propeller shaft from IRD drive flange
and tie shaft aside.
CAUTION: Care must be taken to support
the Tripode joint when removed from the
IRD unit. To avoid damage to gaiter or steel
can, the joint should not be allowed to fully
extend or be dropped.
15.Disconnect breather hose from IRD housing.
16.Position container to collect coolant spillage.17.Release clips and disconnect coolant hoses
from IRD.
18.Remove bolt securing engine lower steady to
IRD support bracket.
19.Remove lower engine steady noting that 'TOP'
mark on engine steady faces uppermost.
20.Remove 3 bolts securing IRD support bracket
to sump.

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
41-8 REPAIRS
10.Reference mark front propeller shaft for
reassembly.
11.Raise one rear wheel for rotation of propeller
shaft to access bolts.
12.Remove 6 nuts and bolts securing propeller
shaft to IRD drive flange.
13.Release propeller shaft from IRD drive flange
and tie shaft aside.
CAUTION: Care must be taken to support
the Tripode joint when removed from the
IRD unit. To avoid damage to gaiter or steel
can, the joint should not be allowed to fully
extend or be dropped.
14.Remove 3 nuts securing mass damper to
pinion housing.
15.Remove mass damper.
16.Disconnect breather hose from IRD housing.
17.Position container to collect coolant spillage.
18.Release clips and disconnect coolant hoses
from IRD.19.Remove bolt securing engine lower steady to
bracket on sump.
20.Remove engine lower steady.
21.Remove 3 bolts securing lower engine steady
bracket to sump and remove bracket.
22.Remove upper bolt securing IRD support
bracket to cylinder block.
23.Remove 5 bolts securing support bracket to
IRD.
M12 7142M12 7144
M12 7165
M12 7166

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

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-11
12.Reference mark front propeller shaft for
reassembly.
13.Raise one rear wheel for rotation of propeller
shaft to access bolts.
14.Remove 6 nuts and bolts securing propeller
shaft to IRD drive flange.
15.Release propeller shaft from IRD drive flange
and tie shaft aside.
CAUTION: Care must be taken to support
the Tripode joint when removed from the
IRD unit. To avoid damage to gaiter or steel
can, the joint should not be allowed to fully
extend or be dropped.
16.Remove nut securing manifold heat shield to
IRD unit.
17.Remove nut securing heat shield to IRD pinion
housing.
18.Remove 2 bolts securing heat shield and
remove heat shield.19.Disconnect breather hose from IRD housing.
20.Position container to collect coolant spillage.
21.Release clips and disconnect coolant hoses
from IRD.
22.Remove bolt securing engine lower steady to
IRD support bracket.
23.Remove lower engine steady noting that 'TOP'
mark on engine steady faces uppermost.