2001 LAND ROVER FREELANDER engine

INTRODUCTION
01-4
HRW Heated Rear Window
ht/HT High tension
HSLA High Strength Low Alloy
IACV Idle Air Control Valve
IAT Intake Air Temperature
ICE In-Car Entertainment
i.dia. Internal diameter
IDM Intelligent Driver Module
IF Intermediate Frequency
in Inch
in
2Square inch
in3Cubic inch
ILT Inlet Throttle
ISO International Organisation for
Standardisation
ITS Inflatable Tubular Structure
k Thousand
kg Kilogramme
kg/h Kilogrammes per hour
km Kilometre
km/h Kilometres per hour
kPa KiloPascal
KS Knock Sensor
lLitre
lb(s) Pounds
lbf Pounds force
lbf.in Pounds force inches
lbf/in
2Pounds per square inch
lbf.ft Pounds force feet
λLambda
lc Low compression
LCD Liquid Crystal Display
LED Light Emitting Diode
LEV Low Emission Vehicle
LH Left-Hand
LHD Left-Hand Drive
LSM Light Switch Module
LVS Liquid Vapour Separator
mMetre
µMicro
MAF Mass Air Flow
MAP Manifold Absolute Pressure
MFU Multi-Function Unit
MFL Multi-Function Logic
max. Maximum
MEMS Modular Engine Management
System
MIG Metal/Inert Gas
MIL Malfunction Indicator Lamp
MPa MegaPascal
MOSFET Metal Oxide Semiconductor Field
Effect Transistor
min. Minimum
- Minus (tolerance)
' Minute (angle)
mm Millimetre
mph Miles per hour MPi Multi-Point injection
MV Motorised Valve
MY Model Year
NAS North American Specification
(-) Negative (electrical)
Nm Newton metre
No. Number
NO
2Nitrogen Dioxide
NO
xOxides of Nitrogen
NTC Negative Temperature
Coefficient
NRV Non Return Valve
OBD On Board Diagnostics
OBM On Board Monitoring
o.dia. Outside diameter
OAT Organic Acid Technology
ORM Off-road Mode
ΩOhm
PAS Power Assisted Steering
PCB Printed Circuit Board
PCV Positive Crankcase Ventilation
PDC Parking Distance Control
PDOP Position Dilation Of Precision
PI Programme Information
PPS Pulse Per Second
PS Programme Service
psi Pounds per square inch
pts. Pints
% Percentage
+ Plus (tolerance) or Positive
(electrical)
±Plus or minus (tolerance)
PTC Positive Temperature Coefficient
PTFE Polytetrafluorethylene
PWM Pulse Width Modulation
RDS Radio Data Service
rRadius
:Ratio
ref Reference
REG Regionalisation
RES Rover Engineering Standards
rev/min Revolutions per minute
RF Radio Frequency
RGB Red / Green / Blue
RH Right-Hand
RHD Right-Hand Drive
ROM Read Only Memory
RON Research Octane Number
ROV Roll Over Valve
ROW Rest Of World
SAE Society of Automotive Engineers
SAI Secondary Air Injection
" Second (angle)
SLABS Self Levelling and Anti-Lock
Brake System
SLS Self Levelling Suspension
SOHC Single Overhead Camshaft
SPE Single Point Entry

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.

GENERAL INFORMATION
03-13
Self-locking bolts and screws
Self-locking bolts and screws, i.e. nylon patched or
trilobular thread can be re-used providing resistance
can be felt when the locking portion enters the
female thread.
Nylon patched bolts and screws have a locking agent
pre-applied to the threads. They are identified by the
presence of a coloured section of thread which
extends for up to 180° around the thread.
Trilobular bolts (i.e. Powerlok) have a special thread
form which creates a slight interference in the
tapped hole or threads of the nut into which it is
screwed.
DO NOT re-use self-locking fasteners in critical
locations (e.g. engine bearings, flywheel). Always
use the correct replacement self-locking nut, bolt or
screw.
DO NOT fit non self-locking fasteners in applications
where a self-locking nut, bolt or screw is specified.
Nut identification
Nut identification
A nut with an ISO metric thread is marked on one
face or on one of the flats of the hexagon with the
strength grade symbol 8, 12, or 14. Some nuts with a
strength grade 4, 5 or 6 are also marked and some
have the metric symbol M on the flat opposite the
strength grade marking.
A clock face system is sometimes used as an
alternative method of indicating the strength grade.
The external chamfers or a face of the nut is marked
in a position relative to the appropriate hour mark on
a clock face to indicate the strength grade.
A dot is used to locate the 12 o'clock position and a
dash to indicate the strength grade. If the grade is
above 12, two dots identify the 12 o'clock position.
When tightening a slotted or castellated nut, never
loosen it to insert a split pin except where
recommended as part of an adjustment. If difficulty is
experienced, alternative washers or nuts should be
selected, or the washer thickness reduced.
Where bearing pre-load is involved, nuts should be
tightened in accordance with special instructions.

GENERAL INFORMATION
03-14
Self-locking nuts
Self-locking nuts, i.e. nylon insert or deferred thread
nuts can be re-used providing resistance can be felt
when the locking portion of the nut passes over the
thread of the bolt or stud.
DO NOT apply heat in an attempt to free deferred
thread nuts or fittings; as well as causing damage to
protective coatings, there is a risk of damage to
electronic equipment and brake linings from stray
heat.
Where self-locking nuts have been removed, it is
advisable to replace them with new ones of the same
type.
Where bearing pre-load is involved, nuts should be
tightened in accordance with special instructions.
Flexible pipes and hoses
General
When removing and installing flexible hydraulic pipes
and hoses, ensure that the following practices are
observed to ensure component serviceability:
lBefore removing any brake or power steering
hose, clean end fittings and area surrounding
them as thoroughly as possible.
lObtain appropriate plugs or caps before
detaching hose end fittings, so that the ports
can be immediately covered to prevent the
ingress of dirt.
lClean hose externally and blow through with
airline. Examine carefully for cracks, separation
of plies, security of end fittings and external
damage. Reject any faulty hoses.
lWhen refitting a hose, ensure that no
unnecessary bends are introduced, and that
hose is not twisted before or during tightening of
union nuts.
lFit a cap to seal a hydraulic union and a plug to
its socket after removal to prevent ingress of
dirt.
lAbsolute cleanliness must be observed with
hydraulic components at all times.
lAfter any work on hydraulic systems, carefully
inspect for leaks underneath the vehicle while a
second operator applies maximum brake
pressure to the brakes (engine running) and
operates the steering.
Do not disconnect any pipes in an air
conditioning refrigeration system unless trained
and instructed to do so. A refrigerant is used
which can cause blindness if allowed to contact
eyes.

GENERAL INFORMATION
03-16
'Oetiker' clips may be removed by bending the tag
(arrowed) and releasing the free end of the clip. Clips
must not be re-used. When fitting new clips, ensure
the clip is correctly positioned on the hose before
tightening and that when the clip is tightened, the tag
is located in the longitudinal slot in the free end of the
clip (arrowed in illustration).
Heat protection
Always ensure that heatshields and protective
sheathing are in good condition. Replace if damage
is evident.
Particular care must be taken when routing hoses
close to hot engine components, such as the exhaust
manifold and the Exhaust Gas Recirculation (EGR)
pipe.
Hoses will relax and deflect slightly when hot; ensure
this movement is taken into account when routing
and securing hoses.
Service tools
General
Special service tools have been developed to
facilitate removal, dismantling and assembly of
mechanical components in a cost effective and time
efficient manner. The use of such special tools also
helps prevent the potential for damage to
components.
Some operations described in this Manual cannot be
carried out properly without the aid of the relevant
service tools.
All orders and enquiries from the United Kingdom
and European countries except Germany, Austria,
Switzerland and Spain and countries not in the
following list should be sent direct to:
SPX UK Ltd.,
Genoa House,
Everdon Park,
Daventry,
Northants,
NN11 5YJ
England
( 00 44 (0) 132 7303467/303455
) 00 44 (0) 1327 706632
e-mail: [email protected]
Overseas orders for the following countries should
be placed with the local SPX distributor.
Germany, Austria and Switzerland
SPX Europe GMBH,
Porschestrasse 4,
63512 Hainburg,
Germany
( 0049 61829590
) 0049 6182959299
Spain
SPX Iberica SA,
C/Francisco Aritio
158 nave 72 (Nudo Oeste),
19004 Guadalajara,
Spain
( 0034 949208381
) 0034 949208327
North America