Replacing the rear crankshaft oil seal (Freelander 1)

Dismantling

1. Unscrew the 3 bolts securing the lower cross member bracket to the pan and remove the bracket.



2. Unscrew the upper bolt securing the transfer case bracket to the cylinder block.

3. Remove the 5 bolts securing the bracket to the transfer case.

4. Unscrew the 3 bolts securing the transfer case bracket to the pan and remove the bracket.

5. Release the transfer case breather hose from the clamp on the dipstick housing.

6. Loosen the clamp and disconnect the cooling system hoses from the transfer case.



7. Unscrew the 4 bolts securing the transfer case to the gearbox and remove the transfer case.





8. Disconnect the connector from the starter.

9. Unscrew the bolt securing the crossmember to the left engine support.

10. Unscrew the 2 nuts and bolts securing the starter to the gearbox, remove the starter, remove the crossmember and the rear cover.



11. Unscrew the 2 bolts securing the engine sump to the gearbox.



12. Mark how the flat washer is installed and unscrew the M6 nut with the bolt securing the front cover to the gearbox.



13. Unscrew the upper front nut with the bolt securing the gearbox to the engine.

14. Unscrew the 2 front nuts with bolts securing the gearbox to the engine, remove the front cover.



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15. Note the position of the engine ground bus and remove the 2 upper gearbox-to-engine mounting bolts.

16. With the help of a partner, remove the gearbox from the engine.



17. Install the LRT-12-190 flywheel stopper onto the engine and secure it with the bolt.

18. Gradually loosen and remove the 6 bolts securing the clutch housing to the flywheel.

19. Remove the clutch cover and driven disc.



20. Remove and discard the 6 flywheel to crankshaft mounting bolts.



21. Remove the flywheel stop LRT-12-190.



22. Using a flat-blade screwdriver without sharp burrs, remove the rear oil seal from the cylinder block and dispose of the oil seal. Avoid damaging the sealing surface of the crankshaft journal.

Installation

1. Remove all traces of oil and sealant from the cylinder block, from the oil seal seat and from the surface of the crankshaft journal.



2. Apply a continuous bead of STC 50550 sealant 1.5mm thick to the new oil seal as shown in the figure.

3. Immediately install the oil seal onto the cylinder block.

CAUTION: Seals must be installed dry.

4. Install the LRT-12-136 mandrel on the crankshaft, secure the mandrel with three bolts.

5. Gradually tighten the LRT-12-136 oil seal crimping bolts until the oil seal is in place and leave the crimping tool in this position for 1 minute.



6. Remove the LRT-12-136 mandrel.

CAUTION: Allow 30 minutes for the sealant to cure before adding oil to the engine or rotating the crankshaft.

7. Using an old drive plate mounting bolt with two 45° notches cut into it, clean the threaded sockets in the crankshaft flange of any remaining thread locking compound.

8. Wipe the flywheel and crankshaft mating surface.

9. Install the flywheel onto the crankshaft.

10. Install the LRT-12-190 flywheel stopper onto the engine and secure it with the bolt.

11. Screw in new flywheel-to-crankshaft mounting bolts and tighten them crosswise to 80 Nm.

12. Place the driven disc on the pressure plate with the 'FLYWHEEL SIDE' marking facing the flywheel.

13. Place the driven disk on the pressure plate and insert the centering mandrel, LRT-12-151.

14. Install the 6 bolts securing the clutch housing to the flywheel, tighten the bolts just enough to hold the driven disk in the center position. Remove the LRT-12-151 centering mandrel from the clutch housing.

15. Gradually tighten the bolts in a criss-cross pattern to a torque of 25 Nm.

16. Remove the flywheel stop LRT-12-190.

17. Wipe the mating surfaces of the engine and gearbox, the pins and their seats.

18. With the help of a partner, install the gearbox onto the engine, paying attention to the mating with the clutch and mounting pins.

19. Install the ground busbar in its place, screw in the two upper bolts securing the gearbox to the engine.

20. Install the front cover, screw in the bolts and tighten the nuts.

21. Tighten the upper bolts and front nuts and bolts to 80 Nm. Tighten the transmission-to-sump bolts to 45 Nm.



22. Place a flat washer on the M6 bolt, screw in the bolt, fit the nut and tighten to 9 Nm.

23. With the help of a partner, install the transfer case onto the gearbox, screw in the bolts and tighten them to a torque of 90 Nm.

24. Install the bracket on the transfer case and on the oil pan, screw in the bracket mounting bolts to the transfer case and tighten them to a torque of 50 Nm, and the bracket mounting bolts to the oil pan to a torque of 45 Nm.

25. Screw in the upper bolt securing the transfer case bracket to the cylinder block and tighten it to a torque of 45 Nm.

26. Install the lower cross member bracket on the tray, screw in the bolts and tighten them to a torque of 100 Nm.

27. Connect the cooling system hoses to the transfer case and secure them with a clamp.

28. Secure the transfer case breather hose to the clamp on the dipstick housing.

29. Clean the starter and gearbox mating surfaces.

30. Install the rear cover on the cylinder block.

31. Install the starter and lower bolt and nut, but do not tighten them at this stage.

32. Install the lower engine crossmember, screw in the crossmember mounting bolt to the left engine mount, but do not tighten it.

33. Insert the upper starter mounting bolt with nut.

34. Tighten the starter mounting bolts and nuts to 80 Nm.

35. Connect the connector to the starter solenoid relay.

36. Add oil to the engine.

MAINTENANCE, Engine oil and oil filter - K1.8.