2001 LAND ROVER FREELANDER lock

GENERAL INFORMATION
03-17
SPX Corporation,
665, Eisenhower Drive,
Owatonna,
MN 55060,
USA
( 0018 772979110
) 0018 005787375
Australia
SPX Australia,
28, Clayton Road,
Notting Hill,
Victoria 3168,
Australia
( 00 (61) 00395446222
) 00 (61) 0395445222
e-mail: [email protected]
Japan and East Asia
Jatek Ltd.,
5 - 53, Minawacho 2-chome,
Kohoku-ku,
Yokohama,
Kanagawa 223-0051,
Japan
( 0081 455627700
) 0081 455627800
Rolling road testing
General
IMPORTANT: Use a four wheel rolling road for
brake testing if possible.
The front and rear wheels cannot be driven
independently due to the viscous coupling. This
eliminates the need for differential lock by
progressively applying more torque to the rear
wheels if the front wheels start to slip.
DO NOT attempt to drive individual wheels with
vehicle supported on floor jacks or stands.
Four wheel rolling road
Provided that front and rear rollers are rotating at
identical speeds and that normal workshop safety
standards are applied, there is no speed restriction
during testing, except any that may apply to the tyres.
Before testing a vehicle with anti-lock brakes on a
four wheel rolling road, disconnect the ABS
modulator. The ABS function will not work, the ABS
warning light will illuminate. Normal braking will be
available.
Two wheel rolling road
ABS will not function on a two wheel rolling road. The
ABS light will illuminate during testing. Normal
braking will be available.
If brake testing on a two wheel rolling road is
necessary, the following precautions should be
taken:
lpropeller shaft to the rear axle is removed/
disconnected;
lneutral selected in gearbox;
lhill descent control not selected.
When checking brakes, run engine at idle speed to
maintain servo vacuum.

GENERAL INFORMATION
03-19
Electrical precautions
General
The following guidelines are intended to ensure the
safety of the operator and ensure the prevention of
damage to the electrical and electronic components
fitted to the vehicle. Where necessary, specific
precautions are detailed in the individual procedures
of this manual.
Equipment
Prior to commencing any test procedure on the
vehicle, ensure that the relevant test equipment is
working correctly and any harness or connectors are
in good condition. It is particularly important to check
the condition of the lead and plugs of mains operated
equipment.
Polarity
Never reverse connect the vehicle battery and
always ensure the correct polarity when connecting
test equipment.
High Voltage Circuits
Whenever disconnecting live ht circuits, always use
insulated pliers and never allow the open end of the
ht lead to contact other components, particularly
ECU's.
Exercise caution when measuring the voltage on the
coil terminals while the engine is running, high
voltage spikes can occur on these terminals.
Connectors and harnesses
The engine compartment of a vehicle is a particularly
hostile environment for electrical components and
connectors:
lAlways ensure electrically related items are dry
and oil free before disconnecting and
connecting test equipment.
lEnsure disconnected multiplugs and sensors
are protected from being contaminated with oil,
coolant or other solutions. Contamination could
impair performance or result in catastrophic
failure.
lNever force connectors apart using tools to
prise apart or by pulling on the wiring harness.
lAlways ensure locking tabs are disengaged
before disconnection, and match orientation to
enable correct reconnection.
lEnsure that any protection (covers, insulation
etc.) is replaced if disturbed.Having confirmed a component to be faulty:
lSwitch off the ignition and disconnect the
battery.
lRemove the component and support the
disconnected harness.
lWhen replacing the component, keep oily hands
away from electrical connection areas and push
connectors home until any locking tabs fully
engage.
Battery disconnection
Before disconnecting the battery, disable the alarm
system and switch off all electrical equipment. If the
radio is to be serviced, ensure the security code has
been deactivated.
CAUTION: To prevent damage to electrical
components, always disconnect the battery
when working on the vehicle's electrical system.
The ground lead must be disconnected first and
reconnected last.
CAUTION: Always ensure that battery leads are
routed correctly and are not close to any
potential chafing points.
Battery charging
Only recharge the battery with it removed from the
vehicle. Always ensure any battery charging area is
well ventilated and that every precaution is taken to
avoid naked flames and sparks.
Ignition system safety precautions
The vehicle's ignition system produces high voltages
and the following precautions should be observed
before carrying out any work on the system:
WARNING: Before commencing work on an
ignition system, ensure all high tension
terminals, adapters and diagnostic equipment
are adequately insulated and shielded to prevent
accidental personal contacts and minimise the
risk of shock. Wearers of surgically implanted
pacemaker devices should not be in close
proximity of ignition circuits or diagnostic
equipment.

GENERAL INFORMATION
03-24
SRS Harnesses and Connectors

CAUTION: Always observe the following
precautions with regards to SRS system
electrical wiring:
lNever attempt to modify, splice or repair
SRS wiring.
lNever install electronic equipment (such as
a mobile telephone, two-way radio or in-car
entertainment system) in such a way that it
could generate electrical interference in the
airbag harness. Seek specialist advice when
installing such equipment.
NOTE: SRS system wiring can be identified by a
special yellow outer sleeve protecting the wires
(black with yellow stripe protective coverings are
sometimes used).
WARNING: Always ensure SRS wiring is routed
correctly. Be careful to avoid trapping or
pinching the SRS wiring. Do not leave the
connectors hanging loose or allow SRS
components to hang from their harnesses. Look
for possible points of chafing.CAUTION: Ensure all SRS harness connectors
are mated correctly and securely fastened. Do
not leave the connectors hanging loose.
Rotary Coupler

CAUTION: Always follow the procedure for fitting
and checking the rotary coupler as instructed in
the SRS repairs section. Comply with all safety
and installation procedures to ensure the system
functions correctly. Observe the following
precautions:
lDo not install a rotary coupler if it is
suspected to be defective.
lDo not attempt to service, modify or repair a
rotary coupler.
lDo not cut, splice or modify the wires
attached to the rotary coupler.
lAlways ensure the rotary coupler
connectors are mated correctly and securely
fastened.
lAlways ensure the battery is disconnected
before working on the rotary coupler.
lDo not unlock and rotate the rotary coupler
when it is removed from the vehicle.
lDo not turn the road wheels when the rotary
coupler is removed from the vehicle.
lAlways ensure the rotary coupler is removed
and installed in its centred position and with
the front road wheels in the straight ahead
position - refer to the SRS repair section for
the correct removal and installation
procedure.
lIf a new rotary coupler is being installed,
ensure the locking tab holding the coupler's
rotational position is not broken; units with a
broken locking tab should not be used.

GENERAL DATA
04-1
GENERAL DATA
Engine - Td4 Diesel
General
Type 2.0 litre in-line direct injection diesel, 16-valve, DOHC, turbocharged
and intercooled
Cylinder arrangement 4 in-line, transverse, No.1 cylinder at front of engine
Bore 84.00 mm (3.307 in.)
Stroke 88.00 mm (3.465 in.)
Capacity 1951 cm
3 (119.05 in3)
Firing order 1-3-4-2
Compression ratio 18:1 ± 0.5:1
Direction of rotation Clockwise, viewed from the front of the engine
Maximum power:
⇒ Up to 03 Model Year - Manual and automatic
gearbox
⇒ 03 Model Year onwards - Manual gearbox
⇒ 03 Model Year onwards - Automatic gearbox82 kW (112 bhp) @ 4000 rev/min.
82 kW (112 bhp) @ 4000 rev/min
80 kW (107 bhp) @ 4000 rev/min
Maximum torque 260 Nm (192 lbf.ft) @ 1750 rev/min.
Maximum governed speed 4800 rev/min.
Maximum overrun speed 5250 rev/min
Idle speed 780 ± 30 rev/min
Dimensions:
⇒ Length
⇒ Width
⇒ Height482 mm (19.0 in)
634 mm (25.0 in)
697 mm (27.4 in)
Glow plugs: 4 off, one per cylinder arranged centrally on inlet side between inlet
valves
Turbocharger Garrett GT2
Fuel injection system: Common rail, direct injection fed by Bosch high pressure delivery
pump
Injection timing Controlled by ECM
Emissions standard ECD3
Valve timing
Inlet valves:
⇒ Opens
⇒ Closes8° BTDC
28° ABDC
Exhaust valves:
⇒ Opens
⇒ Closes38° BBDC
4° ATDC

GENERAL DATA
04-2
Lubrication
Type Wet aluminium die-cast sump, pressure fed
Oil filter Disposable canister with full flow by-pass
Oil cooler Integral with oil filter assembly, connected to vehicle cooling system
Oil pump:
⇒ Type Crankshaft driven, eccentric rotor
⇒ Oil flow rate 30 litres / min. (6.625 gallons/min.)
⇒ Outer rotor to body clearance 0.080 - 0.158 mm (0.0031 - 0.062 in.)
⇒ Peak pressure up to 20 bar (290 lbf.in
2)
Oil pressure at idle:
⇒ Cold - 1000 rev/min. 1.5 bar (21.8 lbf.in
2)
⇒ Operating temperature (minimum) 0.5 bar (7.3 lbf.in
2)
⇒ Regulated pressure 4.2 ±0.5 bar (60.9 ± 7.3 lbf.in
2)
⇒ Pressure at 3500 rev/min (hot) 3.0 - 4.5 bar (43.5 - 65.3 lbf.in
2)
Relief valve opening pressure 4.2 bar (60.9 lbf.in
2)
Low oil pressure switch opening pressure 0.2 - 0.5 bar (2.9 - 7.3 lbf.in
2)
Cylinder block
Type Grey cast iron with hollow beam structure
Cylinder head warp - maximum 0.03 mm (0.001 in.)
Cylinder head bore:
†
⇒ Standard 84.000 - 84.018 mm (3.3071 - 3.3078 in)
⇒⇒ Wear limit 84.040 mm (3.3087 in)
⇒ Intermediate 84.080 - 84.098 mm (3.3102 - 3.3109 in)
⇒⇒ Wear limit 84.120 mm (3.3118)
⇒ 1st.Oversize (Grinding dimension) 84.250 - 84.268 mm (3.3169 - 3.3176 in)
⇒⇒ Wear limit 84.290 mm (3.3185 in)
Cylinder bore ovality (permitted roundness deviation)
†0.01 mm (0.0004 in)
⇒ Wear limit 0.04 mm (0.0016 in)
Cylinder bore taper (permitted conicity)
†0.01 mm (0.0004 in)
⇒ Wear limit 0.04 mm (0.0016 in)
†Measurements at top centre and bottom of bore
Crankshaft
Main journal diameter 60 mm (2.36 in.)
Crankpin journal diameter 44.975 - 45.009 mm (1.7707 - 1.7720 in)
End float 0.08 - 0.163 mm (0.0031 - 0.0064 in.)
Maximum out of round
†0.15 mm (0.006 in.)
Crankshaft seal PTFE
†At centre main journal; crankshaft supported on outer bearing pins

GENERAL DATA
04-6
Engine - K1.8 Petrol
General
Type 1.8 litre petrol, 16-valve DOHC
Cylinder arrangement 4 in-line, transverse, No.1 cylinder at front of engine
Bore 80.00 mm (3.150 in.)
Stroke 89.30 mm (3.516 in.)
Capacity 1796 cm
3 (109.59 in3)
Firing order 1-3-4-2
Compression ratio 10.5 :1 ± 0.5 :1
Direction of rotation Clockwise viewed from the front of the engine
Maximum power 88 kW (118 bhp) @ 5500 rev/min.
Maximum torque 165 Nm (223.7 lbf.ft) @ 2750 rev/min.
Idle speed 775 ± 50 rev/min.
Maximum intermittent engine speed 6750 rev/min.
Weight (fully dressed, wet) 108 kg (238 lb)
Dimensions:
⇒ Length (nominal) 654 mm (25.75 in.)
⇒ Width (nominal) 600 mm (23.62 in.)
⇒ Height (nominal) 615 mm (24.21 in.)
Spark plugs:
⇒ Type NLP 100290
⇒ Gap 1.0 mm ± 0.05 mm (0.039 in. ± 0.002 in.)
Ignition coils:
⇒ Make Nippon Denso - NEC 100730
⇒ Type 2 x twin output coils, plug top mounted; cylinders 1 & 4 and 2 & 3
⇒ Primary resistance (typical) 0.7 Ω
⇒ Secondary resistance (typical) 10 Ω
Fuel injection system:
Type Returnless fuel rail, multi-point fuel injection, electronically controlled
from ECM
Controller MEMS 3 breakerless, electronic, fully mapped engine management
system
Injectors:
⇒ Operating pressure 3.5 bar (50.8 lbf.in
2)
⇒ Fuel flow rate 117 g/min. @ 3.0 bar (4.13 fl.oz/min. @ 43.5 lbf. in
2)
Valve operation Self-adjusting, lightweight hydraulic tappets operated directly by
camshafts
Emissions standard ECD3
Cylinder block:
Material Aluminium alloy
Cylinder liner type Damp, bottom half stepped - sliding fit into lower part of cylinder block
Cylinder liner bore:
⇒ RED grade A 80.000 - 80.015 mm (3.1496 - 3.1501 in.)
⇒ BLUE grade B 80.016 - 80.030 mm (3.1502 - 3.1508 in.)

GENERAL DATA
04-11
Engine - KV6 Petrol
General
Type:
⇒ Up to 03 Model Year
⇒ From 03 Model Year2.5 litre V6, 24 valve, air assisted direct fuel injection petrol, water
cooled, transverse mounted
2.5 litre V6, 24 valve, direct fuel injection petrol, water cooled,
transverse mounted
Cylinder arrangement: 90° V6, numbered from the front of the engine
⇒ Left bank Cylinders 1, 3 and 5
⇒ Right bank Cylinders 2, 4 and 6
Bore (nominal) 80 mm (3.15 in.)
Stroke 82.8 mm (3.26 in.)
Capacity 2497 cm
3 (152.37 in3)
Firing order 1-6-5-4-3-2
Compression ratio 10.5 : 1 ± 0.5 : 1
Direction of rotation Clockwise viewed from front of engine
Maximum power 130 kW (177 bhp) @ 6500 rev/min.
Maximum torque 240.0 Nm (177 lbf.ft) @ 4000 rev/min.
Maximum engine speed:
⇒ Continuous 6500 rev/min.
⇒ Intermittent 6750 rev/min.
Idle speed 750 rev/min. ± 50 rev/min.
Weight (fully dressed, wet) 154 kg (340 lb)
Dimensions (dressed):
⇒ Length (nominal) 770 mm (30.3 in.)
⇒ Width (nominal) 750 mm (29.5 in.)
⇒ Height (nominal) 750 mm (29.5 in.)
Valve operation Self-adjusting lightweight hydraulic tappets operated directly by the
camshafts
Fuel injection system:
⇒ Make - Up to 03 Model Year
⇒ Make - From 03 Model YearSiemens engine management system
Siemens engine management system
⇒ Type - Up to 03 Model Year
⇒ Type - From 03 Model YearMulti-point, air assisted fuel injection controlled by ECM, electro-
mechanical injectors with twin sprays targeted on to back of inlet
valves
Multi-point fuel injection controlled by ECM, electro-mechanical
injectors with quadruple sprays targeted on to back of inlet valves
Inlet manifold Variable geometry
Spark plugs
⇒ Type
⇒ Plug gapNLP 100290
1.0 mm ± 0.05 mm (0.039 in. ± 0.002 in.)
Coils:
⇒ Make - Up to 03 Model Year
⇒ Make - From 03 Model Year
⇒ Type - Up to 03 Model Year
⇒ Type - From 03 Model YearBREMR
Champion BAE 403H
6 x coils (3 x plug top, 3 x remote mounted)
6 x coils (6 x plug top)
Emissions standard ECD3

GENERAL DATA
04-12
Cylinder head
Type Aluminium alloy
Cylinder head gasket * Multi-layer steel
Cylinder head warp:
⇒ Lateral
⇒ Longitudinal0.025 mm (0.001 in)
0.2 mm (0.08 in)
Cylinder head height
Reface height - minimum118.95 - 119.05 mm (4.683 - 4.687 in)
118.95 mm (4.683 in)
Cylinder block
Type Cosworth cast aluminium alloy with bearing ladder bolted to bottom of
block
Cylinder liner type Damp, bottom half stepped - sliding fit into lower part of cylinder block
Cylinder liner bore:
⇒ RED grade A 80.000 - 80.015 mm (3.1496 - 3.1502 in.)
⇒ BLUE grade B 80.015 - 80.030 mm (3.1502 - 3.1508 in.)
Crankshaft
Material / Type Cast spheroidal graphite iron with cold rolled fillets on all journals
except outer mains
Crankshaft end-float
⇒ Service limit0.10 - 0.30 mm (0.004 - 0.012 in.)
0.40 mm (0.016 in.)
Main journal diameter:
⇒ Grade 1 67.743 - 67.749 mm (2.6670 - 2.6673 in.)
⇒⇒ Grade A (Green)
†
⇒⇒ Grade B (Yellow)†
⇒⇒ Grade C (Black)†
⇒ Grade 2 67.737 - 67.743 mm (2.6668 - 2.6670 in.)
⇒⇒ Grade A (Blue)
†
⇒⇒ Grade B (Green)†
⇒⇒ Grade C (Yellow)†
⇒ Grade 3 67.731 - 67.737 mm (2.6666 - 2.6668 in.)
⇒⇒ Grade A (Red)
†
⇒⇒ Grade B (Blue)†
⇒⇒ Grade C (Green)†
Maximum out of round 0.010 mm (0.0004 in.)
Main housing diameter:
⇒ Grade A 71.600 - 71.593 mm (2.8189 - 2.8186 in.)
⇒ Grade B 71.593 - 71.586 mm (2.8186 - 2.8183 in.)
⇒ Grade C 71.586 - 71.579 mm (2.8183 - 2.8181 in.)
Big-end journal diameter:
⇒ Grade A 54.049 - 54.055 mm (2.1279 - 2.1281 in.)
⇒ Grade B 54.043 - 54.049 mm (2.1277 - 2.1279 in.)
⇒ Grade C 54.037 - 54.043 mm (2.1274 - 2.1277 in.)
⇒ Maximum out of round 0.010 mm (0.0004 in.)
Big-end housing diameter:
⇒ Grade 7 57.677 - 57.671 mm (2.2707 - 2.2705 in.)
⇒⇒ Grade A (Green)
*
⇒⇒ Grade B (Blue)*
⇒⇒ Grade C (Red)*
⇒ Grade 8 57.671 - 57.665 mm (2.2705 - 2.2703 in.)
⇒⇒ Grade A (Yellow)
*
⇒⇒ Grade B (Green)*
General