2001 LAND ROVER FREELANDER engine oil

CONTENTS
4CONTENTS
MAINTENANCE ........................................................................................ 10-1
MAINTENANCE
Td4 - Diesel Engine - Under Bonnet View ...................................................................................... 10-1
K1.8 – Petrol Engine – Under Bonnet View .................................................................................... 10-2
KV6 – Petrol Engine – Under Bonnet View .................................................................................... 10-3
Seats and Seat Belts ...................................................................................................................... 10-4
Lamps, Horns and Warning Indicators ........................................................................................... 10-4
Wipers and Washers ...................................................................................................................... 10-5
Handbrake ...................................................................................................................................... 10-5
Alarm Handset Battery.................................................................................................................... 10-6
Road Wheels .................................................................................................................................. 10-6
Tyres ............................................................................................................................................... 10-7
Brake Pads and Calipers ................................................................................................................ 10-7
Brake Fluid...................................................................................................................................... 10-9
Road Wheel Speed Sensors .......................................................................................................... 10-9
Fuel Filter - Petrol ........................................................................................................................... 10-10
Fuel Filter - Diesel........................................................................................................................... 10-10
Fuel Pump and Filter assembly - Diesel - 03 Model Year onwards ................................................ 10-10
Fuel Sedimenter - Diesel - 03 Model Year onwards ....................................................................... 10-10
Door Locks, Hinges, Check Straps and Bonnet Catch ................................................................... 10-11
Anti-freeze ...................................................................................................................................... 10-12
Cooling System and Intercooler...................................................................................................... 10-12
Vent filter - turbocharger boost control solenoid valve - Td4 .......................................................... 10-13
Spark Plugs – K1.8 ......................................................................................................................... 10-13
Spark Plugs – KV6.......................................................................................................................... 10-13
Air Cleaner – Petrol Models ............................................................................................................ 10-13
Ancillary Drive Belt – Td4 ............................................................................................................... 10-14
Ancillary Drive Belt – K1.8 .............................................................................................................. 10-14
Ancillary Drive Belt – KV6 ............................................................................................................... 10-15
Camshaft Timing Belt – K1.8 .......................................................................................................... 10-15
Camshaft Timing Belt – KV6........................................................................................................... 10-16
Brake/Clutch Reservoir ................................................................................................................... 10-16
PAS Fluid Level .............................................................................................................................. 10-17
Intermediate Reduction Drive - Non NAS models .......................................................................... 10-17
Intermediate Reduction Drive - NAS models .................................................................................. 10-18
Manual Gearbox – PG1 .................................................................................................................. 10-18
Manual Gearbox – GETRAG .......................................................................................................... 10-19
Automatic Gearbox – JATCO ......................................................................................................... 10-19
Rear Axle ........................................................................................................................................ 10-20
Clutch Pipes and Unions ................................................................................................................ 10-21
Windscreen and Rear Washer Reservoir ....................................................................................... 10-21
Battery ............................................................................................................................................ 10-21
Engine Oil and Filter – Td4 ............................................................................................................. 10-22
Engine Oil and Filter – K1.8 ............................................................................................................ 10-23
Engine Oil and Filter – KV6 ............................................................................................................ 10-24
Fuel Hoses and Pipes..................................................................................................................... 10-25
Brake Hoses and Pipes ................................................................................................................. 10-26
Check Exhaust System................................................................................................................... 10-26
Suspension ..................................................................................................................................... 10-27
Steering ......................................................................................................................................... 10-28
Road Test ....................................................................................................................................... 10-28
Endorse Service Record ................................................................................................................. 10-30
Report any Unusual Features ......................................................................................................... 10-30

CONTENTS
CONTENTS 5
ENGINE - K SERIES KV6 ......................................................................... 12-3-1
ADJUSTMENTS
Engine oil pressure check ............................................................................................................... 12-3-1
REPAIRS
Camshafts - LH cylinder head......................................................................................................... 12-3-3
Camshafts - RH cylinder head ........................................................................................................ 12-3-5
Inlet camshaft front oil seal ............................................................................................................. 12-3-8
Camshaft rear oil seal ..................................................................................................................... 12-3-9
Pulley - crankshaft ......................................................................................................................... 12-3-10
Crankshaft front oil seal .................................................................................................................. 12-3-11
Crankshaft rear oil seal ................................................................................................................... 12-3-12
Cylinder head gasket - LH .............................................................................................................. 12-3-13
Cylinder head gasket - RH .............................................................................................................. 12-3-16
Camshaft cover gasket - LH - Up to 03MY ..................................................................................... 12-3-20
Camshaft cover gasket - LH - from 03MY ....................................................................................... 12-3-21
Camshaft cover gasket - RH ........................................................................................................... 12-3-23
Cover - engine acoustic ................................................................................................................. 12-3-25
Engine and automatic gearbox - up to 03MY .................................................................................. 12-3-25
Engine and automatic gearbox - from 03MY .................................................................................. 12-3-35
Arm assembly - engine mounting RH ........................................................................................... 12-3-45
Engine mounting - LH ..................................................................................................................... 12-3-46
Hydramount - engine - RH ............................................................................................................. 12-3-47
Engine steady - upper RH ............................................................................................................... 12-3-47
Engine steady - lower ..................................................................................................................... 12-3-48
Torque converter drive plate ........................................................................................................... 12-3-49
Filter - engine oil ............................................................................................................................ 12-3-50
Oil pick-up strainer .......................................................................................................................... 12-3-50
Gasket - oil pump ........................................................................................................................... 12-3-51
Sump - reseal.................................................................................................................................. 12-3-53
Switch - oil pressure ....................................................................................................................... 12-3-54
Oil pressure relief valve .................................................................................................................. 12-3-55
Oil cooler - engine ........................................................................................................................... 12-3-57
Camshaft timing belt ....................................................................................................................... 12-3-58
Camshaft timing belt cover - RH front ............................................................................................. 12-3-66
Camshaft timing belt cover - LH front ............................................................................................. 12-3-67
Camshaft timing belt cover - LH rear .............................................................................................. 12-3-68
Camshaft timing belt cover - RH rear .............................................................................................. 12-3-68
Camshaft rear timing belt - LH cylinder head .................................................................................. 12-3-69
Camshaft rear timing belt - RH cylinder head ................................................................................. 12-3-73
OVERHAUL
Piston assemblies - engine set ....................................................................................................... 12-3-77
Crankshaft front oil seal ................................................................................................................ 12-3-80
Crankshaft rear oil seal ................................................................................................................... 12-3-81
Crankshaft....................................................................................................................................... 12-3-82
Cylinder head gasket - LH .............................................................................................................. 12-3-87
Cylinder head gasket - RH .............................................................................................................. 12-3-91
Cylinder head - decarbonise ........................................................................................................... 12-3-94
Oil pump - Overhaul ........................................................................................................................ 12-3-104
Sump - engine oil ........................................................................................................................... 12-3-106
Camshaft timing belt ....................................................................................................................... 12-3-107

CONTENTS
6CONTENTS
EMISSION CONTROL ............................................................................. 17-1-1
ADJUSTMENTS
Evaporative loss control system (EVAPS) - leak test - NAS........................................................... 17-1-1
REPAIRS
Valve - depression limiter - Td4 ..................................................................................................... 17-1-3
Solenoid - canister purge - KV6 ...................................................................................................... 17-1-4
Charcoal canister - petrol - Non NAS ............................................................................................. 17-1-4
Charcoal canister - NAS ................................................................................................................. 17-1-5
Valve - canister purge - K1.8 .......................................................................................................... 17-1-6
Valve - EGR - Td4 .......................................................................................................................... 17-1-7
Solenoid/modulator valve - EGR - Td4 ........................................................................................... 17-1-8
Thermal valve - exhaust gas recirculation (EGR) -
Td4 Automatic transmission (hot climates) - from 03 MY ............................................................... 17-1-9
Cooler - EGR - Td4 ......................................................................................................................... 17-1-9
Module - tank leakage diagnostic (DMTL) ...................................................................................... 17-1-11
Filter - fuel leak detection pump - KV6 - NAS ................................................................................ 17-1-12
Catalytic converter - RH - KV6 - NAS ............................................................................................ 17-1-12
ENGINE MANAGEMENT SYSTEM - SIEMENS....................................... 18-3-1
REPAIRS
Spark plugs - up to 03MY ............................................................................................................... 18-3-1
Spark plugs - from 03MY ................................................................................................................ 18-3-2
Coil - each - LH bank - up to 03MY ................................................................................................ 18-3-3
Coil - each - LH bank - from 03MY ................................................................................................. 18-3-3
Coil - each - RH bank - up to 03MY ................................................................................................ 18-3-4
Coil - each - RH bank - from 03MY................................................................................................. 18-3-4
Engine control module (ECM) - Non NAS ..................................................................................... 18-3-5
Engine control module (ECM) - fuel - NAS .................................................................................... 18-3-6
Idle Air Control Valve (IACV) ......................................................................................................... 18-3-7
Sensor - intake air temperature (IAT) - NAS .................................................................................. 18-3-8
Sensor - engine coolant temperature (ECT) .................................................................................. 18-3-8
Sensor - crankshaft position (CKP) ............................................................................................... 18-3-9
Sensor - throttle position (TP) ......................................................................................................... 18-3-10
Sensor - thermostat monitoring (TM) - KV6 - NAS ........................................................................ 18-3-11
Sensor - camshaft position (CMP) ................................................................................................. 18-3-12
Sensor - knock (KS) ....................................................................................................................... 18-3-13
Switch - throttle pedal - Non NAS ................................................................................................... 18-3-13
Sensor - combined - manifold absolute pressure/Intake air temperature (MAP/IAT) ..................... 18-3-14
Sensor - throttle position (TP) - NAS - up to 03MY......................................................................... 18-3-15
Sensor - throttle position (TP) - NAS - from 03MY ......................................................................... 18-3-16

CONTENTS
CONTENTS 9
AUTOMATIC GEARBOX - JATCO .......................................................... 44-1
ADJUSTMENTS
Inhibitor switch - adjust ................................................................................................................... 44-1
Gearbox fluid - drain & refill ........................................................................................................... 44-2
Selector cable - adjust .................................................................................................................. 44-3
REPAIRS
Selector housing ............................................................................................................................. 44-5
Gear knob ..................................................................................................................................... 44-6
Selector cable ................................................................................................................................. 44-7
Selector indicator - up to 03 MY ..................................................................................................... 44-8
Selector indicator - from 04MY ....................................................................................................... 44-9
Inhibitor switch ............................................................................................................................... 44-10
ECU ................................................................................................................................................ 44-10
Oil seal - torque converter............................................................................................................... 44-11
Gearbox - KV6 - with engine and gearbox removed ....................................................................... 44-12
Gearbox - KV6 ................................................................................................................................ 44-17
Gearbox - Td4 ................................................................................................................................. 44-23
Fluid pan - reseal ............................................................................................................................ 44-27
Fluid cooler - air blast - Td4 (hot climates) ...................................................................................... 44-28
Fluid cooler - Td4 ............................................................................................................................ 44-30
Fluid cooler - KV6 ........................................................................................................................... 44-31
Hose - fluid cooler .......................................................................................................................... 44-32
DRIVESHAFTS ......................................................................................... 47-1
REPAIRS
Shaft with both joints - LH ............................................................................................................... 47-1
Shaft with both joints - RH ............................................................................................................. 47-3
Gaiter - bell & joint - outer - front..................................................................................................... 47-5
Bell & joint - outer - LH - front ......................................................................................................... 47-5
Gaiter - inner joint ........................................................................................................................... 47-6
Shaft with both joints - rear ............................................................................................................. 47-6
Gaiter - outer - rear ......................................................................................................................... 47-8
Bell & joint - outer - rear .................................................................................................................. 47-8
Gaiter - inner joint - rear .................................................................................................................. 47-9
Propeller shaft assembly ................................................................................................................ 47-9
Propeller shaft - front ..................................................................................................................... 47-11
Propeller shaft - rear ....................................................................................................................... 47-12
Propeller shaft - front /rear - overhaul ............................................................................................. 47-13
Gaiter - sliding joint - front propeller shaft ....................................................................................... 47-14
Viscous coupling assembly ............................................................................................................ 47-15
Support bearing - front ................................................................................................................... 47-16

GENERAL INFORMATION
03-1
GENERAL INFORMATION
General precautions
Dangerous substances
Modern vehicles contain many materials and liquids
which if not handled with care can be hazardous to
both personal health and the environment.
WARNING: Many liquids and other substances
used in motor vehicles are poisonous and should
under no circumstances be consumed and
should, as far as possible, be kept from contact
with the skin. These liquids and substances
include acid, anti-freeze, asbestos, brake fluid,
fuel, windscreen washer additives, lubricants,
refrigerants and various adhesives.
Always read carefully the instructions printed on
labels or stamped on components and obey them
implicitly. Such instructions are included for
reasons of your health and personal safety.
Never disregard them.
WARNING: Many of the fluids used in motor
vehicles, such as coolant, brake fluid and power
steering fluid, are inflammable. Take care not to
spill fluids when topping-up, a fire may result. If
spillage does occur, ensure the area is
thoroughly cleaned before starting the engine.
Synthetic rubber
Many 'O' rings, seals, hoses, flexible pipes and other
similar items which appear to be natural rubber, are
in fact, made of synthetic materials called
Fluoroelastomers.
Under normal operating conditions this material is
safe and does not present a health hazard. However,
if the material is damaged by fire or excessive
heating, it can break down and produce highly
corrosive Hydrofluoric acid which can cause serious
burns on contact with skin.
If skin contact does occur:
lRemove any contaminated clothing
immediately.
lIrrigate effected area of skin with a copious
amount of cold water or limewater for 15 to 60
minutes.
lObtain medical assistance immediately.
Should any material be in a burnt or over-heated
condition, handle with extreme caution and wear
protective clothing (seamless industrial gloves,
protective apron etc.). Decontaminate and dispose of
gloves immediately after use.Lubricating oils
WARNING: Avoid excessive skin contact with used
engine oil. Used engine oil contains potentially
harmful contaminants which may cause skin cancer
or other serious skin disorders.
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats from
the skin, leading to dryness, irritation and dermatitis.
Health protection precautions
The following precautions should be observed at all
times:
lAvoid prolonged and repeated contact with oils,
particularly used engine oils.
lWear protective clothing, including impervious
gloves where practicable.
lDo not put oily rags in pockets.
lAvoid contaminating clothes (particularly those
next to the skin) with oil.
lOveralls must be cleaned regularly. Discard
heavily soiled clothing and oil impregnated
footwear.
lFirst aid treatment should be obtained
immediately for open cuts and wounds.
lUse barrier creams: apply before each work
period to help prevent lubricating oil from
contaminating the skin.
lWash with soap and water to ensure all oil is
removed (propriety skin cleansers and nail
brushes will help).
lUse moisturisers after cleaning; preparations
containing lanolin help replace the skin's natural
oils which have been removed.
lDo not use petrol, kerosene, diesel fuel, gas, oil,
thinners or solvents for cleaning skin.
lIf skin disorders develop, obtain medical advice
without delay.
lWhere practicable, degrease components prior
to handling.
lWear eye protection (e.g. goggles or face
shield) if there is a risk of eye contamination.
Eye wash facilities should be provided in the
close vicinity of the work area.

GENERAL INFORMATION
03-2
Environmental Protection Precautions
It is illegal to pour used oil on to the ground, down
sewers or drains, or into water courses.
Burning of used engine oil in small space heaters or
boilers should only be considered for units of
approved design and in compliance with the
equipment manufacturer's recommendations. The
heating system must meet the regulatory standards
of HMIP for small burners of less than 0.4 MW. If in
doubt check with the appropriate local authority and/
or manufacturer of the approved appliance.
Dispose of used oil and filters through authorised
waste disposal contractors and licensed waste
disposal sites, or through the waste oil reclamation
trade. If in doubt, contact the Local Authority for
advice on disposal facilities.
Safety instructions
Whenever possible, use a lift or pit when working
beneath vehicle, in preference to jacking. Chock
wheels as well as applying parking brake.
Jacking
Always use the recommended jacking points. The
recommended jacking points are shown in
theLIFTING AND TOWING sub-section of the
INFORMATION section.
Always ensure that any lifting apparatus has
sufficient load capacity for the weight to be lifted.
Ensure the vehicle is standing on level ground prior
to lifting or jacking.
Apply the handbrake and chock the wheels.
WARNING: Do not work on or under a vehicle
supported only by a jack. Always support the
vehicle on safety stands.
Do not leave tools, lifting equipment, spilt oil, etc.,
around or on the work bench area. Always keep a
clean and tidy work area.
Brake shoes and pads
Always fit the correct grade and specification of
brake linings. When renewing brake pads and brake
shoes always replace as complete axle sets only.

GENERAL INFORMATION
03-3
Brake hydraulics
Observe the following recommendations when
working on the brake system:
lAlways use two spanners when loosening or
tightening brake pipe or hose connections.
lEnsure that hoses run in a natural curve and are
not kinked or twisted.
lFit brake pipes securely in their retaining clips
and ensure that the pipe run cannot contact a
potential chafing point.
lContainers used for hydraulic brake fluid must
be kept absolutely clean.
lDo not store hydraulic brake fluid in an unsealed
container, it will absorb water and in this
condition would be dangerous to use due to a
lowering of its boiling point.
lDo not allow hydraulic brake fluid to be
contaminated with mineral oil, or put new
hydraulic brake fluid in a container which has
previously contained mineral oil.
lDo not re-use hydraulic brake fluid previously
removed from the system.
lAlways use clean brake fluid or a recommended
alternative to clean hydraulic components.
lFit a blanking cap to a hydraulic union and a
plug to its socket, immediately after
disconnection of pipes and hoses to prevent the
ingress of dirt.
lAbsolute cleanliness must be observed when
working with hydraulic components.
lIt is imperative that the correct brake fittings are
used and that threads of components are
compatible.
Cooling system caps and plugs
Extreme care is necessary when removing engine
cooling system expansion tank caps and coolant
drain or bleed screws when the engine is hot, and
especially if it is overheated.
To avoid the possibility of scalding allow the engine
to cool before attempting coolant cap or plug
removal.
Environmental Precautions
General
This section provides general information which can
help to reduce adverse environmental impacts
incurred through the activities carried out in
workshops.
Emissions to air
Many of the activities that are carried out in
workshops emit gases and fumes which contribute to
global warming, depletion of the ozone layer and/or
the formation of photo-chemical smog at ground
level. By considering and controlling how the
workshop activities are carried out, these gases and
fumes can be minimised, thus reducing the damage
to the environment.
Exhaust fumes
Running car engines is an essential part of workshop
activities and exhaust fumes need to be ventilated to
atmosphere. However, the amount of time engines
are running and the position of the vehicle should be
carefully considered at all times, to reduce the
release of poisonous gases and minimise the
inconvenience to people living nearby.
Solvents
Some of the cleaning agents used are solvent based
and will evaporate to atmosphere if used carelessly,
or if cans are left unsealed. All solvent containers
should be firmly closed when not needed and solvent
should be used sparingly. Suitable alternative
materials may be available to replace some of the
commonly used solvents. Similarly, many paints are
solvent based and the spray should be minimised to
reduce solvent emissions.
Refrigerant
It is illegal to release any refrigerants into the
atmosphere. Discharge and replacement of these
materials from air conditioning units should only be
carried out using the correct equipment.
Checklist
Always adhere to the following:
Engines –
ldon't leave engines running unnecessarily;
lminimise testing times and check where the
exhaust fumes are being blown.

GENERAL INFORMATION
03-5
Local issues
A number of environmental issues will be of
particular concern to residents and other neighbours
close to the site. The sensitivity of these issues will
depend on the proximity of the site and the layout
and amount of activity carried on at the site.
Noise is a major concern and therefore consideration
should be given to the time spent carrying out noisy
activities and the location of those activities that can
cause excessive noise.
Car alarm testing, panel beating, hammering and
other such noisy activities should, whenever
possible, be carried out indoors with doors and
windows shut, or as far away from houses as
possible.
Running vehicle engines may be an outside activity
which could cause nuisance to neighbours because
of both noise and smell.
Be sensitive to the time of day when these activities
are carried out and minimise the time of the noisy
operation, particularly in the early morning and late
evening.
Another local concern will be the smell from the
various materials used. Using less solvent, paint and
petrol could help prevent this annoyance.
Local residents and other business users will also be
concerned about traffic congestion, noise and
exhaust fumes, be sensitive to these concerns and
try to minimise inconvenience from deliveries,
customers and servicing operations.
Checklist
Always adhere to the following:
lidentify where the neighbours who are likely to
be affected are situated;
lminimise noise, smells and traffic nuisance;
lprevent litter by putting waste in the correct
containers;
lhave waste skips emptied regularly.Use of resource
Another environmental concern is the waste of
materials and energy that can occur in day to day
activities.
Electricity for heating, lighting and compressed air
uses resources and releases pollution during its
generation.
Fuel used for heating, running cars or vans and
mobile plant is another limited resource which
consumes large amounts of energy during its
extraction and refining processes.
Water has to be cleaned, piped to site and disposed
of, all of which creates more potential pollution;
Oil, spares, paint etc., have all produced pollution in
the process of manufacture and they become a
waste disposal problem if discarded.
Checklist
Always adhere to the following:
Electricity and heating –
lkeep doors and windows closed in the winter;
lswitch off machinery or lights when not needed;
luse energy efficient heating systems;
lswitch off computers and photocopiers when
not needed.
Fuel –
ldon't run engines unnecessarily;
lthink about whether journeys are necessary and
drive to conserve fuel.
Water –
ldon't leave taps and hose pipes running;
lmend leaks quickly, don't be wasteful.
Compressed air –
ldon't leave valves open;
lmend leaks quickly;
ldon't leave the compressor running when not
needed.
Use of environmentally damaging materials –
lcheck whether a less toxic material is available.
Handling and storage of materials –
lhave the correct facilities available for handling
liquids to prevent spillage and wastage as listed
above;
lprovide suitable locations for storage to prevent
frost damage or other deterioration.