Right cylinder head gasket (Freelander 1)

Dismantling

1. Remove the intake receiver.

MANIFOLDS AND EXHAUST SYSTEM: MOD. K, V6 engine, ENGINE OVERHAUL, Intake manifold seals: vehicles manufactured before May 2003.

2. Remove and discard the timing belt.

ENGINE KV6 - MODIFICATION K, Piston group, Timing belt.

3. Remove the right oxygen sensor connector from the bracket on the coolant pipe and disconnect the connector.



4. In the sequence shown in the figure, unscrew the 4 nuts securing the right exhaust manifold to the cylinder head.

5. Remove the exhaust manifold and discard its gaskets.



6. Unscrew the 4 bolts securing the rear cover of the front timing belt to the right cylinder head and remove the cover.



7. Remove the right cylinder head valve cover gasket.

ENGINE KV6 - MODIFICATION K, Camshafts of the left cylinder head, Valve cover gasket of the right cylinder head.

8. Before May 2003: Remove the 3 nuts and 3 bolts securing the ignition coils to the left intake manifold and disconnect the coil ground wire.

9. Before May 2003: Remove the ignition coils and place them aside.



10. Loosen the clamp, disconnect the steam outlet hose from the right intake manifold and move the hose to the side.



11. Disconnect the injector harness from either the injector protective cover (if provided) or from the lugs on the fuel rail.





12. Unscrew the 2 bolts securing the injector protective cover (if provided) and the right fuel rail to the right intake manifold and remove the cover.



13. Unscrew the 2 bolts securing the fuel rail to the left intake manifold.

14. Release the injectors from the manifolds and carefully place the ramp with the injectors aside.

CAUTION: Always plug the fittings and holes to protect the system from dirt.

15. In the sequence shown in the figure, loosen and unscrew the 8 cylinder head mounting bolts.



16. Remove the cylinder head.

CAUTION: Place the cylinder head on wooden blocks.

17. Remove and discard the cylinder head gasket.

CAUTION: Do not rotate the crankshaft with the left cylinder head installed (and timing belt removed).

18. Install the LRT-12-144 fasteners onto the cylinder liners and tighten them with the cylinder head fastening bolts.

CAUTION: The base of the cylinder liner fasteners must not protrude above the cylinder bore.

Installation

1. Wipe the lower surface of the cylinder head.

CAUTION: Use a special cleaning liquid and a plastic scraper.

2. Unscrew the bolts from the LRT-12-144 cylinder liner fasteners and remove the fasteners.

CAUTION: Do not rotate the crankshaft.

3. Clean the top surface of the cylinder block, the dowel pins and the dowel pin holes.



4. Wash the cylinder head mounting bolts and wipe them dry.

5. Lightly lubricate the threaded portion and bolt heads with clean engine oil.



6. Check that the protrusion of the pins above the plane of the block is within 10-11 mm. Replace the pins if the protrusion does not correspond to the values specified above.

7. Install a new cylinder head gasket onto the cylinder block with the 'TOP' mark facing upwards.

8. With the help of a partner, place the head on the cylinder block and carefully install the right intake manifold onto the left.

9. Carefully insert the cylinder head mounting bolts, DO NOT LOOSE THE BOLTS TO FALL INTO THEIR SOCKETS. Tighten the bolts by hand.



10. Tighten the cylinder head mounting bolts in the sequence shown in the figure:

• Stage 1: 25 Nm
• Stage 2: 25 Nm
• Stage 3: 25 Nm
• Step 4: 180° turn

11. Install the right cylinder head valve cover gasket.

ENGINE KV6 - MODIFICATION K, Camshafts of the left cylinder head, Valve cover gasket of the right cylinder head.

12. Remove the lower O-rings from the injectors and discard them.

13. Wipe the injectors and their seats in the fuel rail.

14. Lubricate new O-rings with castor oil and install them on the injectors.

15. Install the fuel rail assembly and secure the injectors in the intake manifolds.

16. Install the injector guard (if provided) on the right fuel rail and secure the injector harness to the clips on the protective cover.

17. Screw in the bolts securing the fuel rail to the intake manifold and tighten them. Tightening torque 9 Nm.

18. Connect the cooling system vapor bleed hose to the intake manifold and secure it with a clamp.

19. Before May 2003: Install the ignition coils to the left intake manifold.

20. Before May 2003: Install the ground wire, install the bolts and nuts securing the ignition coils to the left intake manifold and tighten them to 9 Nm.

21. Clean the rear timing belt cover mounting bolts and apply STC 50552 sealant to the first three threads.

22. Install the rear belt cover, screw in the bolts and tighten them to a torque of 9 Nm.

23. Install the new timing belt.

ENGINE KV6 - MODIFICATION K, Piston group, Timing belt.

24. Wipe the exhaust manifold and the mating surface on the cylinder head.



25. Install a new exhaust manifold gasket. Install the exhaust manifold, fit the nuts and tighten them to 45 Nm in the sequence shown in the figure.

26. Connect the right oxygen sensor connector, secure the connector to the cooling system pipe bracket.