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Home/Land Rover/Freelander/Land Rover Freelander I рестайлинг (2003-2006)/Repair manual/Mechanical/Reassembly: Removal & Installation
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Reassembly: Removal & Installation Land Rover Freelander I рестайлинг

Mechanical 4 illustrations ~1956 words

Installation

Fit oil pump gasket. See GASKET - OIL PUMP .

Removal

  1. Drain engine oil. See «FILTER - ENGINE OIL»(ref-158807-S42322541582005011200000).
  2. If fitted: Remove 4 nuts securing engine oil cooler to mounting bracket and position oil cooler aside. see scheme 117
  3. Remove bolt securing dipstick tube to cylinder block. see scheme 118
  4. Depress and hold down dipstick tube collar; remove dipstick tube from sump.
  5. Using sequence shown and noting their fitted positions, remove 10 bolts securing sump to lower crankcase. see scheme 120
  6. Using a mallet, gently tap sump sideways to break sealant bond, remove sump. CAUTION: Do not lever between crankcase and sump.
  1. Using a suitable cleaning solvent, clean sump and mating face on lower crankcase. DO NOT use a metal scraper on sealing surfaces.
  2. Apply a 2 mm (0.1 in) bead of sealant, Part No. STC 4600 along center of sump flange, then spread to an even film using a roller. CAUTION: To avoid contamination, assembly should be completed immediately after application of sealant.
  3. Position sump, fit bolts and tighten progressively in the sequence shown to 35 Nm (26 ft. lbs.). see scheme 121
  4. If fitted: Position engine oil cooler to sump mounting bracket, fit and tighten nuts to 25 Nm (18 ft. lbs.).
  5. Position dipstick tube to sump and cylinder block, fit bolt and tighten to 9 Nm (7 ft. lbs.).
  6. Fill engine with oil.
  1. Remove 4 bolts securing engine mounting bracket to engine front plate and remove bracket. (Scheme 245)
  2. Release and remove ancillary drive belt from remaining pulleys.
  3. Remove 2 bolts securing ancillary drive belt tensioner and remove tensioner. see scheme 138
  4. Remove Torx screw securing idler pulley to front mounting plate and remove pulley. see scheme 132
  5. Release alternator battery lead terminal cover, loosen terminal nut and disconnect lead from terminal. see scheme 131
  6. Disconnect multiplug from alternator.
  7. Remove lower bolt and upper nut and bolt securing alternator to front mounting plate.
  8. Release alternator and remove.
  9. Remove 3 bolts securing camshaft timing belt left rear cover and remove cover. see scheme 124
  10. Remove inlet manifold chamber - if fitted. See «30.15.37 SEALS -- INLET MANIFOLD CHAMBER -- UP TO 03MY»(ref-219267-S33433288832006021100000).
  11. Remove 2 bolts securing right rear timing belt cover heat shield to cylinder head; remove heat shield. see scheme 125
  12. Remove 3 bolts securing right rear timing belt cover; remove cover.
  13. Using a socket on crankshaft pulley bolt, rotate crankshaft in a clockwise direction and align the engine SAFE position - notch on crankshaft pulley aligned to the ARROW on front mounting plate. Check that the timing marks on the rear camshaft gears are aligned as illustrated. CAUTION: Do not use the camshaft gear bolts or timing belts to rotate the crankshaft. Do not use the arrow on the oil pump body as a timing reference. see scheme 126
  14. Insert timing pin LRT-12-232 through hole immediately adjacent to side of lower crankcase ensuring that pin is located in hole in drive plate. see scheme 127
  15. Remove 3 bolts securing camshaft timing belt left front cover and remove cover. see scheme 135
  16. Remove 3 bolts securing camshaft timing belt right front cover and remove cover. see scheme 134
  17. Remove bolt securing dipstick tube to cylinder block. see scheme 118
  18. Depress locking collar, release and remove dipstick tube from engine sump.
  19. Assemble LRT-12-161 to LRT-12-199 and secure with clamp bolt. see scheme 136
  20. Insert LRT-12-161 with LRT-12-199 into crankshaft pulley, loosen and remove pulley bolt. CAUTION: Ensure crankshaft does not rotate during above operation.
  21. Remove LRT-12-161 and LRT-12-199 from crankshaft pulley.
  22. Remove crankshaft pulley.
  23. Remove 3 bolts securing camshaft timing belt lower cover to cylinder block and remove cover. see scheme 137
  24. Remove 3 bolts securing engine front mounting plate and lifting bracket to cylinder block. see scheme 142
  25. Remove bolt securing lifting bracket to right cylinder head and remove lifting bracket.
  26. Remove rubber blanking plug from around camshaft timing belt tensioner. see scheme 141
  27. Remove 5 bolts and 2 pillar bolts securing engine front mounting plate to cylinder block. see scheme 143
  28. Remove 2 bolts securing IRD support bracket to engine front mounting plate.
  29. With care, release and remove front mounting plate from engine.
  30. Fit a suitable 1.5 mm diameter pin through hole in tensioner body and into hole in plunger. see scheme 144 NOTE: If holes in body and plunger are not aligned, move tensioner backplate using a broad bladed screwdriver; this will move the plunger sufficiently to align the holes and allow the pin to be inserted.
  31. Remove and discard 2 Patchlok bolts securing tensioner to cylinder block and remove tensioner. CAUTION: Exercise great care when removing bolts, do not apply excessive torque. If bolts appear to be seized, apply suitable anti-seize lubricant prior to removing bolts. DO NOT loosen Allen screw securing tensioner pulley.
  32. If camshaft timing belt is to be refitted, mark direction of rotation on timing belt before removal.
  33. 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. 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.
  34. Remove and discard left and right exhaust camshaft cap seals. see scheme 145
  35. Position tools LRT-12-196 to left and right 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. see scheme 146
  36. Remove and discard bolts retaining front inlet camshaft gears to camshafts.
  37. Remove tools LRT-12-196 from both inlet camshaft gears and exhaust camshafts.
  38. Remove camshaft drive gears and hub assemblies.

Scheme 245

Scheme 245
Scheme 245

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 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.
  2. Fit hubs to camshaft gears and fit gears to camshafts.
  3. Fit new camshaft gear bolts; tighten bolts sufficiently to allow gears to rotate without tipping.
  4. 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.
  5. Fit tool LRT-12-197 into each exhaust camshaft in turn. see scheme 147
  6. Using assistance, rotate each exhaust camshaft slightly and align timing marks on left and right rear camshaft gears. see scheme 148
  7. Remove tool LRT-12-197.
  8. Fit tools LRT-12-175 to left and right rear camshaft gears.
  9. Rotate both front camshaft gears fully clockwise as viewed from front of engine.
  10. 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.
  11. Position an Allen key in tensioner backplate and hold tensioner pulley against timing belt. (Scheme 246)
  12. With assistance, position timing belt tensioner, fit new Patchlok bolts and tighten to 25 Nm (18 ft. lbs.). 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. (Scheme 247) 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: Stage 1 - 27 Nm (20 ft. lbs.) Stage 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 maneuver 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. (Scheme 248): M10 bolt - No. 1 - 25 Nm (18 ft. lbs.) M10 bolt - No. 5 - 45 Nm (33 ft. lbs.) Bolts Nos. 2, 3, 4, 6 and 7 - 85 Nm (63 ft. lbs.)
  23. Position engine lifting bracket, fit bolts securing lifting bracket and front mounting plate to cylinder block and right cylinder head and tighten: M8 bolt - 25 Nm (18 ft. lbs.) M10 bolts - 45 Nm (33 ft. lbs.)
  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 ft. lbs.).
  27. Clean lower timing belt cover.
  28. Position lower timing belt cover, fit and tighten bolts to 9 Nm (7 ft. lbs.).
  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 ft. lbs.).
  33. Remove tools LRT-12-161 and LRT-12-199.
  34. Clean ancillary drive belt tensioner.
  35. Position ancillary belt tensioner, fit bolts and tighten to 25 Nm (18 ft. lbs.).
  36. Clean left and right front timing belt covers.
  37. Position left and right front timing belt covers, fit and tighten bolts to 4 Nm (3 ft. lbs.).
  38. Clean idler pulley, position pulley to engine front mounting plate and tighten Torx bolt to 45 Nm (33 ft. lbs.).
  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 ft. lbs.).
  41. Connect alternator multiplug.
  42. Connect battery lead to alternator, fit and tighten nut to 8 Nm (6 ft. lbs.), fit terminal cover.
  43. Clean left rear timing belt cover.
  44. Position left rear timing belt cover, fit and tighten bolts to 4 Nm (3 ft. lbs.).
  45. Clean right rear timing belt cover.
  46. Position right rear timing belt cover, fit bolts and tighten to 4 Nm (3 ft. lbs.).
  47. Position heat shield, fit bolts and tighten M6 bolt to 9 Nm (7 ft. lbs.) and M8 bolt to 25 Nm (18 ft. lbs.).
  48. Fit inlet manifold chamber - if fitted. See «30.15.37 SEALS -- INLET MANIFOLD CHAMBER -- UP TO 03MY»(ref-219267-S33433288832006021100000).
  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 ft. lbs.).

Scheme 246

Scheme 246
Scheme 246

Scheme 247

Scheme 247
Scheme 247

Scheme 248

Scheme 248
Scheme 248

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