Freelander 1. Manual - part 90

ENGINE - K SERIES KV6

REPAIRS 12-3-51

40. With care, ease camshaft timing belt from

gears using fingers only and remove timing
belt.

CAUTION: Do not rotate crankshaft or
camshafts with timing belt removed and
cylinder heads fitted.

CAUTION: Camshaft timing belt must be
replaced if cylinder head is to be removed or
new drive gears, tensioner or coolant pump
are to be fitted. Camshaft timing belts must
be stored and handled with care. Always
store a camshaft timing belt on its edge with
a bend radius greater than 50 mm (2.0 in).
Do not use a camshaft timing belt that has
been twisted or bent double as this will
damage the reinforcing fibres. Do not use a
camshaft timing belt if debris other than belt
dust is found in timing belt covers. Do not
use a camshaft timing belt if partial engine
seizure has occurred. Do not use a
camshaft timing belt if mileage exceeds
72,000 km (45,000 miles). Do not use an oil
or coolant contaminated timing belt, cause
of contamination must be rectified.

41. Remove and discard LH and RH exhaust

camshaft cap seals.

42. Position tools LRT-12-196 to LH and RH 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.

43. Remove and discard bolts retaining front inlet

camshaft gears to camshafts.

44. Remove tools LRT-12-196 from both inlet

camshaft gears and exhaust camshafts.

45. Remove camshaft drive gears and hub

assemblies.

Refit

NOTE: Following front or rear timing belt
refitment, it is possible that, after rotating the
engine and positioning the crankshaft pulley to
the 'SAFE' position, the timing marks on the
rear timing gears may be misaligned. This
misalignment is acceptable provided that the
timing belt refitting procedure was carried out
correctly.

1. Clean camshaft gears and hubs, crankshaft

gear, tensioner and water pump pulleys.

CAUTION: If the sintered gears have been
subjected to prolonged oil contamination,
they must be soaked in a solvent bath and
then thoroughly washed in clean solvent
before refitting. Because of the porous
construction of sintered material, oil
impregnated in the gears will emerge and
contaminate the belt.

2. Fit hubs to camshaft gears and fit gears to

camshafts. Fit new bolts and tighten sufficiently
to allow gears to rotate without tipping.

ENGINE - K SERIES KV6

12-3-52 REPAIRS

3. Position timing belt to crankshaft gear.

NOTE: To prevent the timing belt from
disengaging from the crankshaft gear when
fitting, fit a suitable wedge between the belt and
oil pump belt guard.

4. Fit tool LRT-12-197 into each exhaust

camshaft in turn.

5. Using assistance, rotate each exhaust

camshaft slightly and align timing marks on LH
and RH rear camshaft gears.

6. Remove tool LRT-12-197 from exhaust

camshaft.

7. Fit tools LRT-12-175 to LH and RH rear

camshaft gears.

8. Rotate both front inlet camshaft gears fully

clockwise as viewed from front of engine.

9. Using fingers only, fit timing belt to gears,

starting at the crankshaft gear and working in
an anti-clockwise direction, keeping the belt run
as taut as possible and turning the camshaft
gears only a minimum amount anti-clockwise to
fit timing belt.

CAUTION: Gears must not be rotated anti-
clockwise more than one tooth.

10. Position an Allen key in tensioner backplate

and hold tensioner pulley against timing belt.

11. With assistance, position tensioner, fit new

Patchlok bolts and tighten to 25 Nm (18 lbf.ft).

CAUTION: Ensure tensioner plunger is
contacting underside of tensioner
backplate.

12. Remove tools LRT-12-175 from rear timing belt

gears.

ENGINE - K SERIES KV6

REPAIRS 12-3-53

13. 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.

14. Tighten front inlet camshaft gear bolts to:

Stage 1 - 27 Nm (20 lbf.ft)

Stage 2 - Further 90

15. Remove tools LRT-12-196 from both inlet

camshaft gears and exhaust camshafts.

16. Remove wedge from between drive belt and oil

pump belt guard.

17. Remove 1.5 mm diameter pin from tensioner.
18. Fit rubber blanking plug around tensioner.
19. Remove timing pin LRT-12-232.
20. 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.

21. Position engine front mounting plate and

manoeuvre plate into position. Fit bolts but do
not tighten at this stage.

22. Fit bolts securing IRD support bracket to front

mounting plate but do not tighten at this stage.

23. Tighten bolts in the sequence shown:

Bolt No. 1 - 25 Nm (18 lbf.ft)

Bolt No. 5 - 45 Nm (33 lbf.ft)

Bolts Nos. 2, 3, 4, 6 and 7 - 85 Nm (63 lbf.ft)

24. Position engine lifting bracket, fit bolts securing

lifting bracket and front mounting plate to
cylinder block and RH cylinder head. Tighten
M10 bolts to 45 Nm (33 lbf.ft) and M8 bolt to 25
Nm (18 lbf.ft).

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. Position A/C compressor to front mounting

plate and cylinder block, align heat shield, fit
and tighten bolts to 25 Nm (18 lbf.ft).

28. Clean lower timing belt cover.
29. Position lower timing belt cover, fit and tighten

bolts to 9 Nm (7 lbf.ft).

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-

199from crankshaft pulley.

34. Clean ancillary drive belt tensioner.
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 Allen bolt to 45
Nm (33 lbf.ft).

39. Position alternator to front mounting plate.

ENGINE - K SERIES KV6

12-3-54 REPAIRS

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. Position PAS pump to front mounting plate, fit

and tighten bolts to 25 Nm (18 lbf.ft).

44. Position PAS pipe to engine front mounting

plate, fit and tighten bolt to 25 Nm (18 lbf.ft).

45. Clean PAS pump pulley mating faces.
46. Position PAS pump pulley, fit and tighten Torx

screws to 9 Nm (7 lbf.ft).

47. Position lower engine steady to sump

mounting, fit and tighten bolt to 100 Nm (74
lbf.ft).

48. Tighten bolt securing lower engine steady to

subframe to 100 Nm (74 lbf.ft).

49. Clean LH rear timing belt cover.
50. Position LH rear timing belt cover, fit and

tighten bolts to 4 Nm (3 lbf.ft).

51. Clean RH rear timing belt cover.
52. position RH rear timing belt cover, fit bolts and

tighten to 4 Nm (3 lbf.ft).

53. Position heat shield, fit bolts and tighten M6 bolt

to 9 Nm (7 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).

54. Fit inlet manifold chamber.

MANIFOLDS & EXHAUST SYSTEMS

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

55. Fit RH road wheel and tighten nuts to 115 Nm

(85 lbf.ft).

56. Fit ancillary drive belt.

CHARGING AND STARTING,

REPAIRS, Ancillary drive belt - KV6.

Camshaft timing belt cover - RH front

$% 12.65.39

Remove

1. Disconnect battery earth lead.
2. Remove ancillary drive belt.

CHARGING AND STARTING,

REPAIRS, Ancillary drive belt - KV6.

3. Remove 3 bolts securing camshaft timing belt

RH front cover and remove cover.

Refit

1. Clean RH front timing belt cover.
2. Position RH front timing belt cover, fit and

tighten bolts to 4 Nm (3 lbf.ft).

3. Fit ancillary drive belt.

CHARGING AND STARTING,

REPAIRS, Ancillary drive belt - KV6.

4. Connect battery earth lead.

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