Land Rover Freelander 2001, Freelander 2003, Freelander 2004 User Manual
Workshop Manual
System Description & Operation
FREELANDER 2001 TO 2004 MY
ONWARDS
WORKSHOP MANUAL - SYSTEM
DESCRIPTION AND OPERATION
Publication Part No. LRL0351 NAS - 5th Edition
Published by Land Rover
©2003 Land Rover
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form,
electronic, mechanical, recording or other means without prior written permission from Land Rover.
CONTENTS
ENGINE - K SERIES KV6......................................................................... 12-3-1
KV6 Engine – General View ........................................................................................................... 12-3-2
KV6 Engine – Internal View ............................................................................................................ 12-3-3
KV6 Engine – Cylinder Block Components..................................................................................... 12-3-4
KV6 Engine – Crankshaft, Sump and Oil Pump Assembly............................................................. 12-3-6
KV6 Engine – Cylinder Head Components ..................................................................................... 12-3-8
KV6 Engine – Manifolds and Engine Cover Components .............................................................. 12-3-10
KV6 Engine – Camshaft Drive Belt Components............................................................................ 12-3-12
Description ...................................................................................................................................... 12-3-13
Operation ........................................................................................................................................ 12-3-17
EMISSION CONTROL - K SERIES KV6 .................................................. 17-3-1
Emission Control Component Layout – Crankcase and Exhaust ................................................... 17-3-1
Emission Control Component Layout – EVAP ................................................................................ 17-3-2
Description ...................................................................................................................................... 17-3-4
ENGINE MANAGEMENT SYSTEM - SIEMENS ...................................... 18-4-1
Engine Management System Component Location........................................................................ 18-4-2
Engine Management System Control Diagram – Sheet 1 of 2 ....................................................... 18-4-4
Engine Management System Control Diagram – Sheet 2 of 2 ....................................................... 18-4-6
Description ...................................................................................................................................... 18-4-8
Operation ........................................................................................................................................ 18-4-41
Cruise Control Component Location............................................................................................... 18-4-43
Cruise Control System Control Diagram......................................................................................... 18-4-44
Cruise Control Description .............................................................................................................. 18-4-46
Cruise Control Operation ................................................................................................................ 18-4-49
FUEL DELIVERY SYSTEM - K SERIES KV6 .......................................... 19-3-1
Fuel Delivery System Component Layout ...................................................................................... 19-3-1
Fuel Delivery System Schematic .................................................................................................... 19-3-2
Description ...................................................................................................................................... 19-3-3
Operation ........................................................................................................................................ 19-3-7
COOLING SYSTEM - K SERIES KV6...................................................... 26-3-1
Cooling System Component Layout - Sheet 1 of 2......................................................................... 26-3-2
Cooling System Component Layout - Sheet 2 of 2......................................................................... 26-3-4
Cooling System Coolant Flow ......................................................................................................... 26-3-5
Description ...................................................................................................................................... 26-3-6
Operation ........................................................................................................................................ 26-3-8
CONTENTS 1
CONTENTS
MANIFOLD AND EXHAUST SYSTEM - K SERIES KV6 ......................... 30-3-1
Inlet Manifold Component Layout ................................................................................................... 30-3-1
Inlet Manifold Chamber Component Layout ................................................................................... 30-3-2
Exhaust System Component Layout – Sheet 1 of 2 ....................................................................... 30-3-3
Exhaust System Component Layout – Sheet 2 of 2 ....................................................................... 30-3-4
Description...................................................................................................................................... 30-3-5
Operation........................................................................................................................................ 30-3-7
INTERMEDIATE REDUCTION DRIVE ..................................................... 41-1
Intermediate Reduction Drive ......................................................................................................... 41-1
Description...................................................................................................................................... 41-2
Operation........................................................................................................................................ 41-3
AUTOMATIC GEARBOX - JATCO........................................................... 44-1
JATCO Automatic Gearbox Component Location .......................................................................... 44-1
JATCO Automatic Gearbox ............................................................................................................ 44-2
JATCO Automatic Gearbox - Exploded View ................................................................................. 44-3
JATCO Automatic Gearbox - Valve Block and Solenoid Valves .................................................... 44-4
JATCO Automatic Gearbox Control Diagram ................................................................................. 44-6
Description...................................................................................................................................... 44-8
Operation........................................................................................................................................ 44-43
DRIVESHAFTS ......................................................................................... 47-1
Drive Shaft and Propeller Shaft Component Layout....................................................................... 47-1
Front Drive Shaft Components ....................................................................................................... 47-2
Rear Drive Shaft Components........................................................................................................ 47-3
Propeller Shaft and VCU Components ........................................................................................... 47-4
Description...................................................................................................................................... 47-5
REAR AXLE AND FINAL DRIVE.............................................................. 51-1
Rear Differential.............................................................................................................................. 51-2
Description...................................................................................................................................... 51-4
STEERING ................................................................................................ 57-1
Steering Components - KV6........................................................................................................... 57-1
Description...................................................................................................................................... 57-2
Operation........................................................................................................................................ 57-10
FRONT SUSPENSION.............................................................................. 60-1
Front Suspension Component Location ......................................................................................... 60-1
Front Suspension Component Detail.............................................................................................. 60-2
Description...................................................................................................................................... 60-4
2CONTENTS
CONTENTS
REAR SUSPENSION................................................................................ 64-1
Rear Suspension Component Location .......................................................................................... 64-1
Rear Suspension Component Detail............................................................................................... 64-2
Description ...................................................................................................................................... 64-4
BRAKES ................................................................................................... 70-1
Brake System Layout (KV6)............................................................................................................ 70-1
Description ...................................................................................................................................... 70-2
Operation ........................................................................................................................................ 70-14
Handbrake Component Layout ....................................................................................................... 70-21
Description ...................................................................................................................................... 70-22
RESTRAINT SYSTEMS............................................................................ 75-1
SRS Component Layout ................................................................................................................. 75-1
SRS Control Diagram ..................................................................................................................... 75-2
Description ...................................................................................................................................... 75-4
Operation ........................................................................................................................................ 75-11
Front Seat Belt Components........................................................................................................... 75-13
Rear Seat Belt Components - Three Door Models ......................................................................... 75-14
Rear Seat Belt Components - Five Door Models ............................................................................ 75-15
Description ...................................................................................................................................... 75-16
HEATING AND VENTILATION................................................................. 80-1
Heating and Ventilation System Component Layout ...................................................................... 80-1
Heater Assembly Components ....................................................................................................... 80-2
Description ...................................................................................................................................... 80-3
Operation ........................................................................................................................................ 80-11
AIR CONDITIONING................................................................................. 82-1
A/C Refrigerant System Component Layout – KV6 Series Engines............................................... 82-1
A/C System Schematic Layout ....................................................................................................... 82-2
A/C Control Component Layout ...................................................................................................... 82-3
A/C System Control Schematic....................................................................................................... 82-4
Description ...................................................................................................................................... 82-6
Operation ........................................................................................................................................ 82-20
WIPERS AND WASHERS ........................................................................ 84-1
Windscreen Wiper Components ..................................................................................................... 84-1
Rear Screen Wiper Components .................................................................................................... 84-2
Washer Components ...................................................................................................................... 84-3
Description ...................................................................................................................................... 84-4
Operation ........................................................................................................................................ 84-7
CONTENTS 3
CONTENTS
CONTROL UNITS ..................................................................................... 86-3-1
Control Unit Locations .................................................................................................................... 86-3-1
Description...................................................................................................................................... 86-3-2
COMMUNICATION DATA BUSES ........................................................... 86-4-1
CAN Bus Control Diagram.............................................................................................................. 86-4-1
Diagnostic Buses (Up To 2002 Model Year) .................................................................................. 86-4-2
Diagnostic Buses (From 2002 Model Year).................................................................................... 86-4-4
Description...................................................................................................................................... 86-4-6
SECURITY................................................................................................. 86-5-1
Locking and Alarm System Component Layout.............................................................................. 86-5-1
Locking and Alarm System Control Diagram.................................................................................. 86-5-2
Description...................................................................................................................................... 86-5-4
Immobilisation System Component Layout .................................................................................... 86-5-11
Immobilisation System Control Diagram......................................................................................... 86-5-12
Description...................................................................................................................................... 86-5-13
Operation........................................................................................................................................ 86-5-16
WINDOWS................................................................................................. 86-6-1
Window Component Layout............................................................................................................ 86-6-1
Side Door Window Control Diagram............................................................................................... 86-6-3
Tail Door Window Control Diagram ................................................................................................ 86-6-5
Description...................................................................................................................................... 86-6-6
Operation........................................................................................................................................ 86-6-9
DRIVING AIDS .......................................................................................... 86-10-1
Park Distance Control..................................................................................................................... 86-10-1
Park Distance Control Control Diagram.......................................................................................... 86-10-2
Description...................................................................................................................................... 86-10-3
PDC System Operation .................................................................................................................. 86-10-7
NAVIGATION SYSTEM ............................................................................ 87-1
Navigation System Component Location........................................................................................ 87-1
Description...................................................................................................................................... 87-2
INSTRUMENTS......................................................................................... 88-1
Instrument Pack Component Location - Front View ....................................................................... 88-1
Instrument Pack Component Location - Front View (2004MY Only) .............................................. 88-2
Instrument Pack Component Layout - Rear View........................................................................... 88-3
Instrument Pack Components - Exploded View ............................................................................. 88-4
Description...................................................................................................................................... 88-5
4CONTENTS
ENGINE - K SERIES KV6DESCRIPTION AND OPERATION
ENGINE - K SERIES KV6
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DESCRIPTION AND OPERATION 12-3-1
ENGINE - K SERIES KV6
KV6 Engine – General View
M12 7452
12-3-2 DESCRIPTION AND OPERATION
KV6 Engine – Internal View
ENGINE - K SERIES KV6
M12 6813
DESCRIPTION AND OPERATION 12-3-3
ENGINE - K SERIES KV6
KV6 Engine – Cylinder Block Components
12-3-4 DESCRIPTION AND OPERATION
1 Clip – coolant pump to thermostat pipe
2 'O' ring – coolant pump to thermostat pipe
3 Pipe – coolant pump to thermostat
4 'O' ring – coolant pump to thermostat pipe
5 Clip – coolant pump to thermostat pipe
6 Thermostat housing
7 'O' ring – coolant outlet elbow to cylinder block
8 Bolt – coolant outlet elbow to cylinder block
9 Coolant outlet elbow
10 'O' ring – thermostat housing to cylinder block
11 Blanking plate – coolant outlet
12 Seal – blanking plate
13 Screw – blanking plate (2 off)
14 Bolt – engine lifting bracket, rear (2 off)
15 Engine lifting bracket – rear
16 Screw – crankshaft rear oil seal (5 off)
17 2nd compression ring
18 Top compression ring
19 Oil control ring
20 Piston
21 Big-end upper bearing shell
22 Big-end bearing cap
23 Bolt – big-end bearing cap to connecting rod
(2 off per piston)
24 Big-end lower bearing shell
25 Crankshaft rear oil seal
26 Cylinder liner (6 off)
27 Dowel – cylinder block to cylinder head (4 off)
28 Cylinder block
29 Dowel – cylinder block to lower crankcase
(4 off)
30 Engine coolant pump
31 Screw – coolant pump to cylinder block (7 off)
32 Seal – coolant pump to cylinder block
ENGINE - K SERIES KV6
DESCRIPTION AND OPERATION 12-3-5
ENGINE - K SERIES KV6
KV6 Engine – Crankshaft, Sump and Oil Pump Assembly
12-3-6 DESCRIPTION AND OPERATION
1 'O' rings – oil filter housing to oil cooler pipes
2 Oil pressure switch
3 Screw – oil pump to cylinder block (16 off)
4 Oil pump and oil filter housing assembly
5 Gasket – oil pump housing
6 Bearing ladder
7 Crankshaft
8 Dipstick
9 Dipstick tube
10 Baffle plate – lower crankcase extension
11 Lower crankcase extension
12 Screw – dipstick tube to cylinder block
13 'O' ring – oil pick-up pipe
14 Oil pick-up pipe with integral strainer
15 Screw – oil pick-up pipe to lower crankcase
16 Connector (quick fit) – dipstick tube to sump
17 Sump
18 Bolt – sump to lower crankcase
(10 off; 5 x short, 5 x long)
19 Oil cooler
20 Bolt – oil cooler to sump (3 off)
21 Oil drain plug
22 Seal – oil drain plug
23 Pipe – oil cooler to oil filter housing
24 Pipe – oil filter housing to oil cooler
25 Oil filter cartridge
26 Bolt (long) – bearing ladder to cylinder block
(8 off)
27 Bolt (short) – bearing ladder to cylinder block
(8 off)
ENGINE - K SERIES KV6
DESCRIPTION AND OPERATION 12-3-7
ENGINE - K SERIES KV6
KV6 Engine – Cylinder Head Components
12
13
14
15
11
1
16
17
18
5
4
3
2
8
9
10
19
6
7
20
42
43
44
39
45
40
41
46
29
27
28
26
30
25
32
31
24
37
21
23
33
34
22
35
36
M12 6646
LH cylinder bank shown, RH cylinder bank similar
12-3-8 DESCRIPTION AND OPERATION
38
1 Rear drive belt inner cover
2 Bolt – camshaft rear drive belt inner cover
(4 off)
3 Camshaft gear – rear inlet
4 Drive belt – rear camshaft
5 Bolt – inlet camshaft gear
6 Bolt – camshaft rear drive belt outer cover
(3 off)
7 Rear drive belt outer cover
8 Bolt – exhaust camshaft gear
9 Camshaft gear – rear exhaust
10 Seal – inlet camshaft, rear oil
11 Inlet camshaft
12 Seal – inlet camshaft, front oil
13 Stud – cylinder head to intake manifold (2 off)
14 Valve stem oil seal – inlet (6 off)
15 Valve spring – inlet (6 off)
16 Valve spring cap – inlet (6 off)
17 Collet – inlet valve (12 off)
18 Tappet – inlet valve (6 off)
19 Camshaft carrier
20 Bolt – cylinder head (8 off)
21 Bolt – camshaft carrier to cylinder head (22 off)
22 Seal – exhaust camshaft, rear oil
23 Exhaust camshaft
24 Tappet – exhaust valve (6 off)
25 Collet – exhaust valve (12 off)
26 Valve spring cap – exhaust (6 off)
27 Valve stem oil seal – exhaust (6 off)
28 Valve spring – exhaust (6 off)
29 Seal – exhaust camshaft, front oil
30 Bolt – camshaft cover (14 off)
31 Seal – oil filler cap
32 Oil filler cap
33 'O' ring – CMP sensor
34 CMP sensor
35 Bolt – CMP sensor
36 Spark plug (3 off)
37 Camshaft cover
38 Gasket – camshaft cover
39 Inlet valve (6 off)
40 Valve seat insert – inlet (6 off)
41 Valve guide – inlet (6 off)
42 Gasket – cylinder head
43 Exhaust valves (6 off)
44 Valve seat insert – exhaust (6 off)
45 Valve guides – exhaust (6 off)
46 Cylinder head
ENGINE - K SERIES KV6
DESCRIPTION AND OPERATION 12-3-9
ENGINE - K SERIES KV6
KV6 Engine – Manifolds and Engine Cover Components
12-3-10 DESCRIPTION AND OPERATION
1 Strap – engine acoustic cover
2 Bolt – engine acoustic cover strap to manifold
chamber
3 Engine acoustic cover
4 Bolt – manifold chamber to RH inlet manifold
(4 off)
5 Manifold chamber
6 Bolt – throttle body assembly to manifold
chamber (4 off)
7 Throttle body assembly
8 Inlet manifold, RH
9 Seal - manifold chamber to LH inlet manifold
(3 off)
10 Guide block – HT lead
11 Stud – HT lead guide block/acoustic cover
fixing
12 Inlet manifold, LH
13 Bolt – inlet manifold to cylinder head LH (7 off)
14 Gasket - inlet manifold to cylinder head (LH)
15 Fuel rail
16 Bolt – inlet manifold to cylinder head
17 Gasket – inlet manifold to cylinder head, RH
18 'O' ring - inlet manifold to top cover RH (3 off)
ENGINE - K SERIES KV6
DESCRIPTION AND OPERATION 12-3-11
ENGINE - K SERIES KV6
KV6 Engine – Camshaft Drive Belt Components
1 Bolt – timing gear to inlet camshaft (RH)
2 Hub – camshaft front timing gear (RH)
3 Camshaft front timing gear (RH)
4 Drive belt (front) backplate cover – RH
5 Engine mounting bracket
6 Bolt – engine mounting bracket to front plate
(4 off)
7 Cover plate – drive belt
8 Blanking plug
9 Engine front plate
10 Engine lifting bracket – front
11 Cover – lower drive belt
12 Drive belt (front) backplate cover – LH
13 Camshaft front timing gear (LH)
12-3-12 DESCRIPTION AND OPERATION
14 Hub – camshaft front timing gear (LH)
15 Idler pulley – drive belt
16 Crankshaft timing gear
17 Drive belt – front
18 Front drive belt outer cover (LH)
19 Screw – front drive belt outer cover to inner
cover, LH (3 off)
20 Front drive belt outer cover (RH)
21 Screw – front drive belt outer cover to inner
cover, RH (3 off)
22 Tensioner assembly – front drive belt
23 Bolt – timing gear to inlet camshaft (LH)
ENGINE - K SERIES KV6
Description
General
The KV6 is of all aluminium construction, with a 90° V configuration. The KV6 uses long cylinder head bolts engaging
in threads 70 mm below the mating face of the cylinder block to attach the cylinder head to the cylinder block. This
ensures sufficient structural stiffness to take advantage of the compressive strength of aluminium alloy and minimise
tensile loadings. There are 8 cylinder head bolts for each cylinder head, located below the camshafts.
The engine features 24 valves, sequential fuel injection, liquid cooling and is transverse mounted. It is controlled by
a Siemens engine management system utilising a range of sensors to constantly monitor and optimise engine
performance.
+ ENGINE MANAGEMENT SYSTEM - SIEMENS, DESCRIPTION AND OPERATION, Description.
Cylinder Block Components
The cylinder block components are described below:
Cylinder Block and Main Bearing Ladder
The cylinder block is constructed of an aluminium alloy and is cast in three sections:
l Cylinder block.
l Main bearing ladder.
l Lower crankcase extension.
For strength and rigidity, the main bearing ladder is manufactured from special alloy A357TF as used in manufacturing
components in the aerospace industry. The main bearing ladder is secured to the cylinder block with 16 bolts, thus
creating a very rigid crankcase 'box'. A separate outer crankcase extension adds further strength to the lower end of
the cylinder block. The lower crankcase extension is sealed to the underside of the cylinder block, using jointing
compound, and secured with 10 bolts. Fitted to the lower crankcase is an aluminium alloy sump.
Pistons and Cylinder Liners
The aluminium alloy, thermal expansion, lightweight pistons, with semi-floating gudgeon pins, are offset to the thrust
side and are carried on forged steel connecting rods. Pistons and cylinder liners are supplied in two grades, 'A' and
'B' and are also colour coded to assist identification. The pistons are marked to ensure they are correctly oriented in
the cylinder liner; the 'FRONT' mark should be toward the front of the engine.
The cylinder block is fitted with 'damp' cylinder liners, the bottom stepped half of the cylinder liner being a sliding fit
into the lower part of the cylinder block. The liners are sealed in the block with a bead of sealant applied around the
stepped portion of the cylinder liner. The top of the cylinder liner is sealed by a multi-layer steel cylinder head gasket
when the cylinder head is fitted.
The cylinder liner diameters are smaller than the big-end forging of the connecting rods and need to be removed
complete with pistons and connecting rods from the cylinder block.
Connecting Rods
The KV6 engine utilises forged steel H-sectioned connecting rods, with the gudgeon pin being an interference fit in
the small end of the connecting rod. The big-ends are horizontally split.
Big-end bearing diametric clearance is controlled by selective bearing shells with three grades of thickness. The bigend upper and lower bearing shells are plain with locating tags.
DESCRIPTION AND OPERATION 12-3-13
ENGINE - K SERIES KV6
Piston Rings
Each piston is fitted with two compression rings and an oil control ring. The top compression rings are chrome-plated
steel. The 2nd compression rings are chrome-plated cast iron. The oil control rings have stainless steel top and
bottom rails and integral expander rings.
Crankshaft, Sump and Oil Pump Components
The crankshaft and sump components are described below:
Crankshaft
The short, stiff crankshaft is supported on four main bearings, with each pair of crankpins mutually offset by 30° to
give equal firing intervals. Cast in Spheroidal Graphite (SG) iron, the crankshaft has cold rolled fillets on all journals,
except the outer mains, for toughness and failure resistance. End-float is controlled by thrust washer halves at the top
and bottom of the rear main bearing.
Main Bearings
Oil grooves are provided in the upper halves of all the main bearing shells to supply oil, via drillings in the crankshaft,
to the connecting rod big-end bearings. The lower halves of the bearing shells in the bearing ladder are plain.
Sump
The cast aluminium sump is a wet-type, sealed to the lower crankcase extension using sealant applied to the sump
flange. The sump is fixed to the lower crankcase extension using 10 bolts. A baffle plate is fitted in the lower crankcase
extension to minimise the effects of oil slosh.
An oil pick-up with integral strainer is located in the centre of the sump oil well, as a source for the supply of engine
lubrication oil to the oil pump. Oil is sucked up though the end of the pick–up and strained to prevent solid matter from
entering the oil pump.
Oil Pump
The oil pump is directly driven from the crankshaft. The oil pump housing includes the oil pressure relief valve, oil filter,
oil pressure switch and return/supply outlets for the engine oil cooler.
Oil Filter
A full-flow, disposable canister-type oil filter is attached to the oil pump housing at the front of the engine.
Oil Cooler
A liquid cooled oil cooler keeps the engine lubrication oil cool, under heavy loads and high ambient temperatures.
The oil cooler is cooled by the engine cooling system and attached to a bracket secured to the front of the sump by
three bolts. Oil is delivered to and from the oil cooler through hoses connected to the oil pump housing. Hoses from
the engine cooling system are connected to two pipes on the oil cooler for the supply and return of coolant.
Oil Pressure Switch
The oil pressure switch is located in a port at the outlet side of the oil filter. It detects when a safe operating pressure
has been reached during engine starting and initiates the illumination of a warning light in the instrument pack if the
oil pressure drops below a given value.
12-3-14 DESCRIPTION AND OPERATION
ENGINE - K SERIES KV6
Cylinder Head Components
The cylinder head components are described below:
Cylinder Head
The cross-flow cylinder heads are based on a four valve, central spark plug combustion chamber, with the inlet ports
designed to induce swirl and control the speed of the induction charge. This serves to improve combustion and hence
fuel economy, performance and exhaust emissions.
LH and RH cylinder heads are identical castings.
Camshafts
Twin camshafts on each cylinder bank are retained by a camshaft carrier, line bored with the cylinder head. The
camshafts are located by a flange which also controls end-float. A crossover drive for the exhaust camshaft, from the
rear of the inlet camshaft is by a short toothed belt, which allows for a much shorter and simpler run for the main
camshaft drive belt at the front of the engine.
The exhaust camshaft drive gears have dampers integral with the gear to minimise torsional vibration. The inlet
camshaft for the LH cylinder head incorporates a reluctor which is used in conjunction with the Camshaft Position
(CMP) sensor to measure engine position. The CMP sensor is bolted to the LH camshaft cover.
+ ENGINE MANAGEMENT SYSTEM - SIEMENS, DESCRIPTION AND OPERATION, Description.
Cylinder Head Gasket
The KV6 utilises a multi-layer stainless steel cylinder head gasket. The gasket comprises four stainless steel
functional layers, and a stainless steel distance layer to maintain fitted thickness. A full embossment profile is
employed to seal the combustion gases and half embossments are used to provide a durable fluid seal. Sealing
characteristics are further enhanced by the application of a fluro-elastomer surface coating to all layers of the gasket.
Hydraulic Tappets
Self-adjusting, lightweight, hydraulic tappets are fitted on top of each valve and are operated directly by the camshaft.
The valve stem oil seals are moulded onto a metal base which also acts as the valve spring seat on the cylinder head.
Valves
The exhaust valves are of the carbon break type. A machined profile on the valve stem removes any build up of carbon
in the combustion chamber end of the valve guide. All valve seats are machined in three planes, improving valve to
seat sealing.
Camshaft Cover and Engine Cover Components
The camshaft cover and engine cover components are described below:
Acoustic Cover
A moulded plastic acoustic cover is fitted over the engine to absorb engine generated noise. Foam is bonded on the
inside surface of the acoustic cover and a rubber seal is fitted around the oil filler cap.
The acoustic cover is located on the engine by two rubber studs on the underside of the acoustic cover. A rubber
strap, at the rear of the engine, and two quick release fasteners, at the front of the acoustic cover, secure the acoustic
cover in position.
Resonators and part of the engine intake duct are integrated into the acoustic cover, and the engine air filter is
installed in a compartment below a lid secured with two Torx bolts.
A metal foil heatshield is installed on the underside of the acoustic cover.
A rubber duct connects the engine intake duct in the acoustic cover to the RH inner wing. A further duct is installed
between the inner and outer wings to draw engine air from the base of the A post.
DESCRIPTION AND OPERATION 12-3-15
ENGINE - K SERIES KV6
Throttle Body Assembly
The throttle body is an electrically actuated unit controlled by the Engine Control Module (ECM). The position of the
throttle plate is controlled by a DC motor and a return spring integrated into the throttle body. Two feedback
potentiometers supply throttle plate position signals to the ECM for closed loop control.
Four Torx bolts secure the throttle body to the inlet manifold chamber. A rubber seal, keyed into a groove in the inlet
manifold chamber, ensures the joint is air tight.
Inlet Manifold Chamber
The inlet manifold chamber is a sealed plastic assembly. The inlet manifold chamber combines plenum resonance for
good low speed torque, with variable length primary tracts for optimum mid and high speed torque.
The throttle body assembly feeds into a 'Y' piece which separates into two secondary inlet pipes. The secondary pipes
feed into two main plenums, one for each bank of three cylinders. At the closed end of the plenums is a balance valve,
controlled by an electric actuator, that connects the two plenums together.
The variable intake system uses valves and actuators to vary the overall tract length of the inlet manifold chamber.
The aluminium alloy inlet manifolds are sealed to each cylinder head with gaskets and to the inlet manifold chamber
with 'O' rings and seals.
+ MANIFOLD AND EXHAUST SYSTEM - K SERIES KV6, DESCRIPTION AND OPERATION, Description.
12-3-16 DESCRIPTION AND OPERATION
ENGINE - K SERIES KV6
Operation
Lubrication Circuit
The lubrication system is of the full-flow filtration, force fed type.
Oil is drawn, via a strainer and pick-up pipe in the sump, through the bearing ladder and into a crankshaft driven oil
pump which has an integral pressure relief valve. The strainer in the pick-up pipe prevents any ingress of foreign
particles from passing through to the inlet side of the oil pump and damaging the oil pump and restricting oil drillings.
The oil pressure relief valve in the oil pump opens if the oil pressure becomes excessive and diverts oil back around
the pump.
Pressurised oil is pumped through a full-flow cartridge type oil filter, mounted on the oil pump housing. The lubrication
system is designed so that a higher proportion of oil flow is directed to the cylinder block main oil gallery while a lower
proportion of oil flow, (controlled by a restrictor in the oil filter housing), is directed to the engine oil cooler. The
remainder of the oil flow from the outlet side of the oil filter is combined with the return flow from the oil cooler before
being passed into the cylinder block main oil gallery.
The main oil gallery has drillings that direct the oil to the main bearings. Cross drillings in the crankshaft main bearings
carry the oil to the connecting rod big-end bearings.
The oil pressure switch is located at the outlet side of the oil filter housing to sense the oil pressure level before the
oil flow enters the main gallery in the engine block. A warning lamp in the instrument pack is illuminated if low oil
pressure is detected.
Oil at reduced pressure is directed to each cylinder bank via two restrictors in the cylinder block/cylinder head locating
dowels, one at the front on the LH bank and the other at the rear on the RH bank. Oil then passes through a drilling
in the cylinder head to the camshaft carrier, where it is directed via separate galleries to the camshaft bearings and
hydraulic tappet housings. Return oil from the cylinder head drains into the sump via the cylinder head bolt passages.
Crankcase Ventilation
A positive crankcase ventilation system is used to vent blow-by gas from the crankcase to the air intake system. The
blow-by gas passes through a gauze oil separator in the camshaft cover, and then through hoses into the throttle
housing and inlet manifold.
+ EMISSION CONTROL - K SERIES KV6, DESCRIPTION AND OPERATION, Description.
DESCRIPTION AND OPERATION 12-3-17
ENGINE - K SERIES KV6
Crankshaft Oil Supply
1 Cylinder block main oil gallery
2 Cross drillings to crankshaft main bearings
3 Oil pick-up pipe with integral strainer
4 Oil cooler
5 Oil cooler supply pipe
12-3-18 DESCRIPTION AND OPERATION
6 Oil filter cartridge
7 Oil cooler return pipe
8 Oil pressure switch
9 Oil pump with integral oil pressure relief valve
ENGINE - K SERIES KV6
Cylinder Head Component Oil Supply
1 From RH cylinder block main gallery
2 LH cylinder head camshafts
3 From LH cylinder block main gallery
4 RH cylinder head camshafts
DESCRIPTION AND OPERATION 12-3-19
ENGINE - K SERIES KV6
12-3-20 DESCRIPTION AND OPERATION
EMISSION CONTROL - K SERIES KV6
EMISSION CONTROL - K SERIES KV6DESCRIPTION AND OPERATION
Emission Control Component Layout – Crankcase and Exhaust
1 Crankcase breather hose to intake duct
2 Crankcase breather hose to inlet manifold
3 Catalytic converters
DESCRIPTION AND OPERATION 17-3-1
EMISSION CONTROL - K SERIES KV6
Emission Control Component Layout – EVAP
A = Vehicles up to 2002.5 Model Year
B = Vehicles from 2002.5 Model Year
17-3-2 DESCRIPTION AND OPERATION
EMISSION CONTROL - K SERIES KV6
1 Fuel tank vent pipes
2 Two-way valve
3 Purge valve
4 Recirculation pipe
5 DMTL to air filter vent pipe
6 Fuel tank to vapour separator vent pipe
7 DMTL
8 Canister to DMTL vent pipe
9 Canister support bracket
10 Vapour separator to canister vent pipe
11 EVAP canister
12 Canister to purge valve vent pipe
13 Air filter
14 Vapour separator
DESCRIPTION AND OPERATION 17-3-3
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