Content .. 79 80 81 82 ..

Freelander 1. Manual - part 81

ENGINE - K SERIES KV6

REPAIRS 12-3-15

20. Fit cylinder liner clamps LRT-12-144 and

secure with cylinder head bolts.

CAUTION: Ensure that feet of clamps do not
protrude over bores.

Refit

1. Clean cylinder head mating face.

CAUTION: Use suitable gasket removal
spray and a plastic scraper.

2. Remove bolts securing cylinder liner clamps

LRT-12-144 to cylinder block and remove
clamps.

CAUTION: Do not rotate crankshaft.

3. Clean cylinder block face and dowel holes.
4. Clean cylinder head bolts and wipe dry.
5. Lightly lubricate threads and beneath heads of

cylinder head bolts with clean engine oil.

6. Fit 2 new metal locating dowels supplied with

replacement cylinder head gasket.

7. Check that fitted height of dowels is between 10

to 11 mm (0.40 to 0.43 in) above cylinder block
top face.

8. Fit new cylinder head gasket onto cylinder

block with the word 'TOP' uppermost.

9. With assistance, fit cylinder head and carefully

position LH inlet to RH inlet manifold.

10. Carefully enter cylinder head bolts, DO NOT

DROP. Screw bolts into place by hand.

11. Tighten cylinder head bolts progressively in the

sequence shown to :

Stage 1 - 25 Nm (18 lbf.ft)

Stage 2 - Tighten in the same sequence to
25 Nm (18 lbf.ft)

Stage 3 -Tighten in the same sequence to
25 Nm (18 lbf.ft)

Stage 4 - Using an angle torque gauge,
tighten bolts in the same sequence a further
180

12. Fit LH camshaft cover gasket.

ENGINE - K SERIES KV6, REPAIRS,

Camshaft cover gasket - LH.

13. Remove and discard 'O' rings from injectors.
14. Clean injectors and injector locations in fuel rail.
15. Lubricate new 'O' rings with castor oil and fit to

injectors.

ENGINE - K SERIES KV6

12-3-16 REPAIRS

16. Position fuel rail assembly and secure injectors

to inlet manifolds.

17. Position injector protection cover - if fitted to RH

fuel rail and secure injector harness to
protection cover or fuel rail with clips.

18. Fit bolts securing fuel rail to inlet manifolds and

tighten to 9 Nm (7 lbf.ft).

19. Position CMP sensor bracket, fit and tighten

bolt to 9 Nm (7 lbf.ft).

20. Connect CMP sensor multiplug and secure to

bracket.

21. Connect breather hose to LH inlet manifold.
22. Connect coolant bleed hose to inlet manifold

and secure with clip.

23. Position ignition coils to LH inlet manifold.
24. Position earth lead, fit nuts and bolts securing

ignition coils to LH inlet manifold and tighten to
9 Nm (7 lbf.ft).

25. Position ht lead guide bracket, fit and tighten

special bolt.

26. Connect ht leads to spark plugs and secure ht

leads in guide clips.

27. Clean camshaft timing belt cover backplate

bolts and apply Loctite 242 to the first 3 threads.

28. Position backplate, fit and tighten bolts to 9 Nm.
29. Fit camshaft timing belt.

ENGINE - K SERIES KV6, REPAIRS,

Camshaft timing belt.

30. Fit LH exhaust manifold gasket.

MANIFOLDS & EXHAUST SYSTEMS

- K SERIES KV6, REPAIRS, Gasket - exhaust
manifold - LH - Non NAS.

MANIFOLDS & EXHAUST SYSTEMS

- K SERIES KV6, REPAIRS, Gasket(s) -
exhaust manifold - LH - NAS.

31. Fit inlet manifold chamber.

MANIFOLDS & EXHAUST SYSTEMS

- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber.

32. Fill cooling system.

COOLING SYSTEM - K SERIES KV6,

ADJUSTMENTS, Coolant - drain and refill.

33. Check engine oil level and top-up if necessary.

MAINTENANCE, MAINTENANCE,

Engine Oil and Filter – KV6.

Cylinder head gasket - RH

$% 12.29.03

Remove

1. Disconnect battery earth lead.
2. Drain cooling system.

COOLING SYSTEM - K SERIES KV6,

ADJUSTMENTS, Coolant - drain and refill.

3. Remove inlet manifold chamber.

MANIFOLDS & EXHAUST SYSTEMS

- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber.

4. Remove RH exhaust manifold gasket.

MANIFOLDS & EXHAUST SYSTEMS

- K SERIES KV6, REPAIRS, Gasket - exhaust
manifold - RH - Non NAS.

MANIFOLDS & EXHAUST SYSTEMS

- K SERIES KV6, REPAIRS, Gasket(s) -
exhaust manifold - RH - KV6 - NAS.

5. Remove camshaft timing belt.

ENGINE - K SERIES KV6, REPAIRS,

Camshaft timing belt.

6. Remove 4 bolts securing RH front timing belt

cover backplate to cylinder head and remove
backplate.

ENGINE - K SERIES KV6

REPAIRS 12-3-17

7. Depress locking collar and release breather

hose from RH inlet manifold.

8. Remove RH camshaft cover gasket.

ENGINE - K SERIES KV6, REPAIRS,

Camshaft cover gasket - RH.

9. Release clip and disconnect coolant bleed

hose from RH inlet manifold, position hose
aside.

10. Release injector harness clips from injector

protection cover - if fitted or from bosses on fuel
rail.

11. Remove 2 bolts securing protection cover - if

fitted and RH fuel rail to RH inlet manifold,
remove cover.

ENGINE - K SERIES KV6

12-3-18 REPAIRS

12. Remove 2 bolts securing fuel rail to LH inlet

manifold.

13. Release injectors from manifolds and carefully

lay fuel rail and injectors aside.

CAUTION: Always fit plugs to open
connections to prevent contamination.

14. Using sequence shown, progressively loosen

and remove 8 cylinder head bolts.

15. With assistance, remove cylinder head

assembly.

CAUTION: Support both ends of cylinder
head on blocks of wood.

16. Remove and discard cylinder head gasket.
17. Remove and discard 2 cylinder head locating

dowels.

Note: Replacement dowels are supplied with
new cylinder head gasket.

CAUTION: Do not rotate crankshaft whilst
LH cylinder head is fitted.

18. Fit cylinder liner clamps LRT-12-144 and

secure with cylinder head bolts.

CAUTION: Ensure that feet of clamps do not
protrude over bores.

Refit

1. Clean cylinder head mating face.

CAUTION: Use suitable gasket removal
spray and a plastic scraper.

2. Remove bolts securing cylinder liner clamps

LRT-12-144 to cylinder block and remove
clamps.

CAUTION: Do not rotate crankshaft.

3. Clean cylinder block mating face and dowel

holes.

4. Clean cylinder head bolts and wipe dry.
5. Lightly lubricate threads and beneath heads of

cylinder head bolts with clean engine oil.

6. Fit 2 new locating dowels supplied with

replacement cylinder head gasket.

Content .. 79 80 81 82 ..