2001 LAND ROVER FREELANDER exhaust

ENGINE - K SERIES KV6
OVERHAUL 12-3-113
11.Position an Allen key in tensioner backplate
and hold tensioner pulley against timing belt.
12.With assistance, position timing belt tensioner,
fit new Patchlok bolts and tighten to 25 Nm (18
lbf.ft).
CAUTION: Ensure tensioner plunger is
contacting underside of tensioner
backplate.
13.Remove tools LRT-12-175 from rear timing belt
gears.
14.Fit tools LRT-12-196 to both front inlet
camshaft gears and into the end of each
exhaust camshaft.
CAUTION: Special tools must be fitted when
tightening or loosening gear retaining bolts,
otherwise damage to camshafts may occur.
15.Tighten front inlet camshaft gear bolts to:
lStage 1 - 27 Nm (20 lbf.ft)
lStage 2 - Further 90°
16.Remove tools LRT-12-196 from both inlet
camshaft gears and exhaust camshafts.17.Remove wedge from between drive belt and oil
pump belt guard.
18.Remove 1.5 mm diameter pin from tensioner.
19.Clean exhaust camshaft front cap seal
locations and fit new cap seals.
CAUTION: The sealing edge of the cap seal
and mating face must be clean and dry.
20.Position engine front mounting plate and
manoeuvre plate into position; fit bolts but do
not tighten at this stage.
21.Fit bolts securing IRD support bracket to front
mounting plate; do not tighten bolts at this
stage.
22.Tighten bolts in the sequence shown:
lM10 bolt - No.1 - 25 Nm (18 lbf.ft)
lM10 bolt - No. 5 - 45 Nm (33 lbf.ft)
lBolts Nos. 2, 3, 4, 6 and 7 - 85 Nm (63 lbf.ft)
23.Position engine lifting bracket, fit bolts securing
lifting bracket and front mounting plate to
cylinder block and RH cylinder head and
tighten to:
lM8 bolt - 25 Nm (18 lbf.ft)
lM10 bolts - 45 Nm (33 lbf.ft)
24.Fit rubber blanking plug around tensioner.
25.Clean end of dipstick tube.
26.Position dipstick tube to sump and cylinder
block, fit bolt and tighten to 9 Nm (7 lbf.ft).
27.Clean lower timing belt cover.
28.Position lower timing belt cover, fit and tighten
bolts to 9 Nm (7 lbf.ft).
29.Remove timing pin LRT-12-232.
30.Clean crankshaft pulley.
31.Fit crankshaft pulley to crankshaft gear and
ensure that the indent on pulley locates over
the lug on crankshaft gear.
32.Fit crankshaft pulley bolt and washer, position
LRT-12-161 with LRT-12-199 into crankshaft
pulley. Tighten pulley bolt to 160 Nm (118
lbf.ft).
33.Remove tools LRT-12-161 and LRT-12-199.
34.Clean ancillary drive belt tensioner.

ENGINE - K SERIES KV6
12-3-114 OVERHAUL
35.Position ancillary belt tensioner, fit bolts and
tighten to 25 Nm (18 lbf.ft).
36.Clean LH and RH front timing belt covers.
37.Position LH and RH front timing belt covers, fit
and tighten bolts to 4 Nm (3 lbf.ft).
38.Clean idler pulley, position pulley to engine
front mounting plate and tighten Torx bolt to 45
Nm (33 lbf.ft).
39.Position alternator to front mounting plate.
40.Fit bolt and nut and bolt securing alternator to
front mounting plate and tighten to 45 Nm (33
lbf.ft).
41.Connect alternator multiplug.
42.Connect battery lead to alternator, fit and
tighten nut to 8 Nm (6 lbf.ft), fit terminal cover.
43.Clean LH rear timing belt cover.
44.Position LH rear timing belt cover, fit and
tighten bolts to 4 Nm (3 lbf.ft).
45.Clean RH rear timing belt cover.
46.Position RH rear timing belt cover, fit bolts and
tighten to 4 Nm (3 lbf.ft).
47.Position heat shield, fit bolts and tighten M6 bolt
to 9 Nm (7 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).
48.Fit inlet manifold chamber - if fitted.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.
49.Position ancillary drive belt to crankshaft and
alternator pulleys.
50.Position engine mounting front bracket to
engine front plate and tighten bolts to 45 Nm
(33 lbf.ft).

EMISSION CONTROL
17-1-8 REPAIRS
Solenoid/modulator valve - EGR - Td4
$% 17.45.04
Remove
1.Disconnect battery earth lead.
2.Remove inlet manifold gaskets.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Gaskets - induction
manifold.
3.Disconnect multiplug from EGR solenoid valve.
4.Remove 2 bolts securing EGR solenoid bracket
to cylinder block.
5.Identify and disconnect vacuum hoses.
6.Remove 2 nuts and remove EGR solenoid
valve from bracket.Refit
1.Fit EGR solenoid valve to bracket and secure
with nuts.
2.Position EGR solenoid valve, identify and
connect vacuum hoses and tighten bolts to 10
Nm (7.5 lbf.ft).
3.Connect multiplug to EGR solenoid valve.
4.Fit inlet manifold gaskets.
+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Gaskets - induction
manifold.
5.Connect battery earth lead.

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
17-1-12 REPAIRS
Filter - fuel leak detection pump - KV6 -
NAS
$% 17.45.42
Remove
1.Disconnect battery earth lead.
2.Remove RH rear wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
3.Remove nut and release filter from bracket.
4.Release clip and remove filter from pipe.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
Refit
1.Fit filter to pipe and secure with clip.
2.Fit filter to bracket and tighten nut to 3 Nm (2.2
lbf.ft).
3.Fit wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
4.Connect battery earth lead.
Catalytic converter - RH - KV6 - NAS
$% 17.50.01
Remove
1.Position vehicle on 4 post ramp.
2.Disconnect battery earth lead.
3.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
4.Release pre catalyst H02S harness from clips.
5.Release and disconnect HO2S multiplug.
6.Remove intermediate pipe and silencer.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Intermediate
pipe - NAS.
7.Remove 3 bolts and remove LH heat shield.
M19 3484

EMISSION CONTROL
REPAIRS 17-1-13
8.Remove 2 bolts and remove RH heat shield.
9.Release post catalyst HO2S harness from
clips.
10.Release and disconnect post catalyst HO2S
multiplug.
11.Remove 2 bolts securing pipe clamp and
remove clamp.12.Remove 2 nuts securing catalyst, remove
catalyst and discard gasket.
NOTE: Do not carry out further dismantling if
component is removed for access only.
13.Identify and remove both H02S from catalyst.
Refit
1.Clean H02S and mating faces.
2.Fit both H02S and tighten to 55 Nm (40 lbf.ft).
3.Clean catalyst and mating face.
4.Using a new gasket, fit catalyst and fit nuts but
do not tighten at this stage.
5.Fit clamp, fit bolts but do not tighten at this
stage.
6.Connect post catalyst H02S multiplug and fit to
bracket.
7.Fit harness into clips.
8.Fit heat shields and tighten bolts to 10 Nm (7
lbf.ft).
9.Fit intermediate pipe and silencer.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Intermediate
pipe - NAS.
10.Tighten nuts securing catalyst to manifold to 50
Nm (37 lbf.ft).
11.Tighten bolts securing clamp to 10 Nm (7 lbf.ft).
12.Connect pre catalyst H02S multiplug and fit to
bracket.
13.Fit harness into clips.
14.Fit acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
15.Connect battery earth lead.
M19 3482

ENGINE MANAGEMENT SYSTEM - SIEMENS
REPAIRS 18-3-13
Sensor - knock (KS)
$% 18.30.28
Remove
1.Disconnect battery earth lead.
2.Remove LH inlet manifold.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket - inlet
manifold - LH.
3.Disconnect KS multiplug.
4.Note the routing of each KS harness.
5.Remove 2 bolts securing KS to cylinder block
and remove sensors.
Refit
1.Clean KS and mating faces on cylinder block.
2.Position KS, ensure that harnesses are
correctly routed, fit and tighten bolts to 25 Nm
(18 lbf.ft).
3.Connect KS multiplug.
4.Fit LH inlet manifold.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket - inlet
manifold - LH.
5.Connect battery earth lead.
Switch - throttle pedal - Non NAS
$% 18.30.36
Remove
1.Remove 2 nuts securing throttle pedal
assembly to bulkhead.
2.Release clip securing throttle inner cable to
throttle pedal and disconnect inner cable from
pedal.
3.Disconnect multiplug from throttle pedal switch.
4.Remove throttle pedal assembly from vehicle.

FUEL DELIVERY SYSTEM - PETROL
19-2-12 REPAIRS
Sensor - heated oxygen (H02S) - pre-
catalyst - LH - KV6 - Non NAS
$% 19.22.16
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Release and disconnect HO2S multiplug.
4.Release HO2S harness from clip.
5.Remove HO2S from LH exhaust manifold.Refit
1.Clean HO2S and exhaust manifold mating
face.
2.Fit HO2S and tighten to 55 Nm (41 lbf.ft).
3.Connect multiplug to HO2S, and secure to
support bracket and harness clip.
4.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Remove stand(s) and lower vehicle.