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Freelander 1. Manual - part 99

ENGINE - K SERIES KV6

OVERHAUL 12-3-87

20. Insert each valve into its respective guide.
21. Extend valve head 15 mm (0.6 in) out of guide

and position DTI gauge to rear of valve head.

22. Move valve towards front of cylinder head and

zero gauge ensuring that stylus of gauge
remains in contact with valve head.

23. Move valve towards rear of cylinder head,

record gauge reading obtained to give valve
stem to guide clearance 'B'.

GENERAL DATA, Engine – KV6

Petrol.

24. Remove valves ensuring they are retained in

their fitted order.

25. Renew valves and/or guides as necessary.
26. To replace valve guides support cylinder head

face down on wooden blocks.

27. Position LRT-12-519-3 in tappet bore and drift

out valve guide using LRT-12-519-1.

CAUTION: Retain guides in their fitted
order.

28. Identify type of valve guide fitted: 'A' - Standard

production 'B' - Service replacement.

CAUTION: Standard production valve
guides A must be replaced with service
replacement guides B.

29. Locate valve guide in valve guide bore with

identification groove towards valve seat and
position depth gauge LRT-12-519-2 onto valve
guide.

CAUTION: Cylinder head and valve guides
must be at room temperature when fitting
guides.

30. Position nylon guide LRT-12-519-3 in cylinder

head, press guide into bore using driver LRT-
12-519-1 until depth gauge contacts cylinder
head.

M12 6890

LRT-12-519-1

LRT-12-519-3

M12 6892

LRT-12-519-2

LRT-12-519-1

LRT-12-519-3

ENGINE - K SERIES KV6

12-3-88 OVERHAUL

31. Check that fitted height of valve guide, 'A', is

6.00 mm (0.24 in).

32. Check condition of valve seats and existing

valves that are to be re-used.

33. Renew valve seat inserts as necessary.

CAUTION: Do not damage counterbore
when removing insert.

34. Cool replacement valve seat inserts using

liquid nitrogen and press into cylinder head in
one continuous operation.

CAUTION: Do not heat cylinder head.
Inserts must not stand proud of combustion
face on completion of cutting operation.

35. Cut valve seats using a suitable pilot and the

following cutters:

- To cut first angle

- Make final cut and remove any burrs

- To narrow seat and obtain correct

valve seat width

36. Check valve seat width and face angle:

Seat width - 'A' - Inlet = 1.2 mm (0.05 in);
Exhaust = 1.6 mm (0.06 in)

Valve face angle - 'B' - Inlet and exhaust =
45

37. Lap each valve to its seat using grinding paste.

38. Apply Prussian Blue to valve seat, insert valve

and press it into position several times without
rotating. Remove and check valve for even and
central seating: seating position shown by
Prussian Blue should be in the centre of valve
face: a: High towards stem, increase 60

cut

and restore seat width. b: Low towards edge,
increase 45

cut and restore seat width. Lap

and recheck valve seating.

39. Check valve stem fitted height - 'A'.

GENERAL DATA, Engine – KV6

Petrol.

CAUTION: If valve stem fitted height is
above service limit, fit new valve and re-
check. If still over limit, renew valve seat
insert.

40. Clean valve springs and lubricate valves.

Reassembly

1. Lubricate new valve stem oil seals with clean

engine oil.

2. Using tool LRT-12-071 fit new valve stem oil

seals.

3. Fit valves.

M12 7894

ENGINE - K SERIES KV6

OVERHAUL 12-3-89

4. Fit spring and spring cap.

5. Position LRT-12-034 and adapter LRT-12-

034/1to spring cap and compress valve spring.

6. Fit collets.
7. Release valve spring and remove tool LRT-12-

034.

8. Using a wooden dowel and mallet, lightly tap

top of each valve two or three times to seat
valves and collets.

9. Thoroughly clean and lubricate hydraulic

tappets with clean engine oil. Fit hydraulic
tappets to original bores in cylinder head.

10. Ensure that mating faces of camshaft carrier

and cylinder head are clean and dry.

11. Lubricate camshafts and bearing journals with

clean engine oil.

12. Position camshafts in cylinder head with rear

timing gear drive slots in each camshaft facing
towards the centre as shown.

CAUTION: Ensure camshafts are in their
correct fitted locations. Camshafts are
colour coded - Inlet - Orange; Exhaust -
Blue.

13. Apply continuous thin beads of sealant, Part

No. STC 4600, to paths on camshaft carrier as
shown. Spread sealant to an even film using a
roller.

CAUTION: To avoid contamination,
assembly should be completed immediately
after application of sealant.

14. Position camshaft carrier, fit and progressively

tighten bolts in the sequence shown to 10 Nm
(7.5 lbf.ft).

ENGINE - K SERIES KV6

12-3-90 OVERHAUL

15. Noting that the front camshaft oil seals are

black in colour and the rear oil seals are red, fit
new camshaft oil seals using LRT-12-203 and
LRT 12-148A

CAUTION: Oil seals must be fitted dry. Do
not use tool LRT-12-148 for fitting seals.

16. Clean camshaft timing belt cover backplate

bolts and apply Loctite 242 to the first 3 threads.

17. Position camshaft timing belt rear cover

backplates to cylinder head, fit and tighten bolts
to 9 Nm (7.5 lbf.ft).

18. Fit spark plugs.
19. Clean rear camshaft gears and mating faces on

camshafts.

CAUTION: If sintered gears have been
subjected to prolonged oil contamination,
they must be soaked in solvent 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 timing belts.

20. Place gears inverted on a flat surface, with the

locating lugs on the gears positioned as
illustrated.

21. Keeping the timing marks aligned, position

timing belt onto gears.

22. Position LRT-12-195 between the gears, turn

centre nut sufficiently to spread drive belt.

23. Invert gears and timing belt and position LRT-

12-175 to camshaft gears.

24. Check that locating lugs are still aligned and

remove LRT-12-195 from between camshaft
gears.

Content .. 97 98 99 100 ..