2001 LAND ROVER FREELANDER gearbox

TORQUE WRENCH SETTINGS
06-20
Manual Gearbox – Getrag
+ Apply sealant, Part No. STC 4600 to threads
TORQUE DESCRIPTION METRIC IMPERIAL
Earth lead to gearbox bolt 25 Nm 18 lbf.ft
Engine LH mounting to body bolts (KV6) 48 Nm 35 lbf.ft
1st gear switch to gearbox 24 Nm 18 lbf.ft
Gearbox drain plug 35 Nm 26 lbf.ft
Gearbox casing end cover Torx bolts 25 Nm 18 lbf.ft
Gearbox filler / level plug 35 Nm 26 lbf.ft
Gearbox closing plate bolts 10 Nm 7 lbf.ft
Gearbox to engine bolts 85 Nm 63 lbf.ft
Gearbox to LH engine mounting bolts (KV6) 85 Nm 63 lbf.ft
Gear change cover bolts 25 Nm 18 lbf.ft
Gearbox mounting bracket to gearbox bolts 85 Nm 63 lbf.ft
Gearbox mounting bracket to gearbox bolts 100 Nm 74 lbf.ft
Gearbox mounting bracket to LH engine mounting through bolt 100 Nm 74 lbf.ft
Gearbox to engine bolts 85 Nm 63 lbf.ft
Gearbox rear cover Torx bolts
+25 Nm 18 lbf.ft
Gear change cover to selector shaft Torx bolts
+25 Nm 18 lbf.ft
LH engine mounting to gearbox bracket bolts 100 Nm 74 lbf.ft
Release bearing sleeve bolts 12 Nm 9 lbf.ft
Reverse lamp switch to gearbox 24 Nm 18 lbf.ft

TORQUE WRENCH SETTINGS
06-21
Intermediate Reduction Drive
+ Apply sealant, Part No. STC 4600 to threads
TORQUE DESCRIPTION METRIC IMPERIAL
Drain plug35 Nm 26 lbf.ft
Exhaust heatshield to exhaust mounting bracket 45 Nm 33 lbf.ft
Exhaust heatshield to IRD screws (Td4) 30 Nm 22 lbf.ft
Exhaust heatshield to IRD nut (K1.8 and KV6) 45 Nm 33 lbf.ft
Filler / level plug35 Nm 26 lbf.ft
IRD unit to gearbox bolts 90 Nm 66 lbf.ft
IRD end cover bolts
+30 Nm 22 lbf.ft
IRD support bracket to cylinder block bolt (K1.8) 48 Nm 35 lbf.ft
IRD support bracket to cylinder block bolt (K1.8) 48 Nm 35 lbf.ft
IRD support bracket to IRD bolts (Td4)
⇒ M8
⇒ M1030 Nm
50 Nm22 lbf.ft
37 lbf.ft
IRD support bracket to IRD bolts (K1.8 and KV6) 50 Nm 37 lbf.ft
IRD support bracket to sump (K1.8 and KV6) 88 Nm 65 lbf.ft
Lower engine steady to IRD support bracket bolts 100 Nm 74 lbf.ft
Manifold heatshield to IRD support bracket bolts (K1.8 and KV6) 9 Nm 6.5 lbf.ft
Manifold heatshield to IRD support bracket bolts (K1.8 and KV6) 25 Nm 18 lbf.ft
Manifold heatshield to pinion housing nut (KV6) 45 Nm 33 lbf.ft
Manifold heatshield to IRD (Td4) 30 Nm 22 lbf.ft
Breather pipe bracket screw 9 Nm 7 lbf.ft
Mass damper to pinion housing nuts (K1.8) 25 Nm 18 lbf.ft
Pinion nut150 Nm 111 lbf.ft
Pinion housing nuts 25 Nm 18 lbf.ft
Propeller shaft to IRD flange bolts 40 Nm 30 lbf.ft

TORQUE WRENCH SETTINGS
06-22
Automatic Gearbox – Jatco
†Tighten in sequence.
+ Apply sealant, Part No. STC 4600 to threads
TORQUE DESCRIPTION METRIC IMPERIAL
Air blast cooler assembly to chassis bolts:
⇒ Lower10 Nm 7.5 lbf.ft
⇒ Upper5 Nm 3.5 lbf.ft
Air blast cooler fan cowl to matrix bolts 5 Nm 3.5 lbf.ft
Air blast cooler fan motor to cowl bolts 5 Nm 3.5 lbf.ft
Air blast cooler multiplug mounting bracket nut 10 Nm 7.5 lbf.ft
Air blast cooler pipe union nuts 25 Nm 18 lbf.ft
Crankshaft Position (CKP) Sensor 9 Nm 7 lbf.ft
Closing panel to gearbox panel bolt 10 Nm 7.5 lbf.ft
Drive plate to converter bolts 45 Nm 33 lbf.ft
Earth lead to gearbox housing bolt 25 Nm 18 lbf.ft
Fluid cooler to mounting bracket bolts (KV6) 25 Nm 18 lbf.ft
Fluid cooler mounting bracket bolts (KV6):
⇒ M825 Nm 18 lbf.ft
⇒ M1285 Nm 63 lbf.ft
Fluid cooler mounting bolts (Td4):
⇒ 2 off45 Nm 33 lbf.ft
⇒ 1 off25 Nm 18 lbf.ft
Fluid cooler hoses to gearbox 18 Nm 13 lbf.ft
Fluid cooler hose unions 18 Nm 13 lbf.ft
Fluid pan bolts
† +7 Nm 5 lbf.ft
Gearbox closing plate bolt (Td4) 10 Nm 7.5 lbf.ft
Gearbox drain plug 45 Nm 33 lbf.ft
Gearbox level plug 14 Nm 10 lbf.ft
Gearbox housing to sump 85 Nm 63 lbf.ft
Gearbox to engine bolts 85 Nm 63 lbf.ft
Gearbox mounting bracket bolts 85 Nm 63 lbf.ft
Gearbox mounting through bolt 100 Nm 74 lbf.ft
Inhibitor switch bolts 3 Nm 2.2 lbf.ft
IRD cooling hose retainer bolt (KV6) 25 Nm 18 lbf.ft
IRD support bracket mounting bolts
† (KV6) 50 Nm 37 lbf.ft
IRD support bracket to engine front mounting bracket bolts
† (KV6) 50 Nm 37 lbf.ft
IRD support bracket to sump bolts
† (KV6) 45 Nm 33 lbf.ft
IRD to gearbox bolts (KV6) 80 Nm 59 lbf.ft
Manifold heatshield to IRD support bracket (KV6):
⇒ Bolts9 Nm 7 lbf.ft
⇒ Nut45 Nm 33 lbf.ft
Manifold heatshield to IRD pinion housing nut (KV6) 25 Nm 18 lbf.ft
Selector housing nuts 10 Nm 7.5 lbf.ft
Selector cable trunnion nut 6 Nm 4.5 lbf.ft
Selector lever to gearbox selector shaft nut 25 Nm 18 lbf.ft
Starter motor to gearbox bolts 45 Nm 33 lbf.ft
Torque converter access plate bolts 9 Nm 7 lbf.ft

LIFTING AND TOWING
08-1
LIFTING AND TOWING
Jacking
The following instructions must be carried out before
raising the vehicle off the ground:
lUse a solid level surface.
lApply parking brake.
lSelect 1st. gear in main gearbox and ensure
HDC is not selected.
CAUTION: To avoid damage to under body
components of the vehicle, adhere to the
following jacking procedures:
DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS:
lBumpers
lBrake or Fuel lines
lExhaust pipe
lSuspension components
lSteering rack and linkages
lFuel tank
lEngine sump
lGearbox
lIRD unit
Jack or support vehicle only on approved jacking
points as detailed in the following illustration:
Front (hydraulic jack) and side (vehicle jack) jacking
pointsSafety stand positions under longitudinal members
Rear (hydraulic jack) and side (vehicle jack) jacking
points
Vehicle jack
The jack provided with the vehicle is only intended to
be used in an emergency, for changing a tyre. Do
NOT use the jack for any other purpose. Refer to the
Owner's Handbook for vehicle jack location points
and procedure. Never work under a vehicle only
supported by the vehicle jack.
Hydraulic jack
A hydraulic jack with a minimum 1500 kg (3,300 lbs)
load capacity must be used.
WARNING: Do not work on or under a vehicle
supported only by a jack. Always support the
vehicle on safety stands.

LIFTING AND TOWING
08-2
Raising the front of a vehicle
Position the cup of the hydraulic arm under the
centre of the front body crossmember assembly.
Use jack to raise front road wheels to enable safety
stands to be installed under the front end of each
longitudinal member.
Carefully lower jack until vehicle sits securely on
safety stands.
Before working on the underside of a vehicle re-
check the stability of the vehicle on the stands.
Use the reverse procedure when removing a vehicle
from stands.
NOTE: For some repair operations it may be
necessary to use a jack to support the engine under
the sump. In this case, a block of wood should be
used on the jack to protect the sump.
Raising the rear of a vehicle
Position cup of hydraulic arm under the centre of the
rear subframe crossmember at the position
identified by the embossed arrows.
Use jack to raise rear road wheels to enable safety
stands to be installed under the rear ends of the
body longitudinal members.
Carefully lower jack until vehicle sits securely on
safety stands.
Before working on the underside of a vehicle, re-
check the stability of the vehicle on the stands.
Use the reverse procedure when removing a vehicle
from stands.
Wheel-free lift
Locate the lifting pads under the ends of the body
longitudinal members. Raise the ramp to support the
weight of the vehicle, ensure the vehicle is secure on
the lifting pads, then raise the ramp to the required
height.
Towing
General
The vehicle has permanent four wheel drive. The
following instructions must be adhered to:
Towing the vehicle on all four wheels with driver
operating steering and brakes
lTurn ignition key to position '1' to release
steering lock and then to position 'II' to enable
the brake lights, wipers and direction indicators
to be operated, if necessary.
l Select neutral in gearbox and ensure HDC (hill
descent control) is deselected.
lSecure tow rope, chain or cable to towing eye.
lRelease the parking brake.
CAUTION: The brake servo and power assisted
steering system will not be functional without the
engine running. Greater pedal pressure will be
required to apply the brakes and the steering
system will require greater effort to turn the front
road wheels. The vehicle tow connection should
only be used under normal road conditions,
'snatch' recovery should be avoided.
Suspended tow by breakdown vehicle
Mark propeller shaft drive flanges and mating flanges
with identification lines to enable the propeller shaft
to be refitted in its original position.
Remove the propeller shaft fixings then remove the
shaft from the vehicle.
CAUTION: To prevent vehicle damage, rear
propeller shaft MUST BE removed.

LIFTING AND TOWING
08-4
Emergency starting
WARNING: Battery fluid (electrolyte) contains
sulphuric acid. It may cause severe burns if it
gets on your skin or in your eyes. Wear
protective clothing and a face shield.
If electrolyte gets on your skin or clothes,
immediately rinse it off with water.
If electrolyte gets in your eyes, immediately flush
eyes with water for at least 15 minutes and seek
medical help.
To Jump Start - Negative Ground Battery
Position vehicles so that jump leads will reach,
ensuring that vehicles DO NOT TOUCH,
alternatively a fully charged slave battery may be
positioned on the floor adjacent to the vehicle.
Ensure that:
lthe ignition and all electrical accessories are
switched off
lthe parking brake is applied and neutral is
selected on gearbox
Connect the jump leads as follows:
WARNING: Making final cable connection could
cause an electrical arc, which if made near
battery could cause an explosion.
aConnect one end of first jumper cable to
positive (+) terminal of booster battery.
bConnect other end of first jumper cable to
positive (+) terminal of discharged battery.
cConnect one end of second jumper cable to
negative terminal of booster battery.
dConnect other end of second jumper cable to a
good earth point on the engine, NOT TO
NEGATIVE TERMINAL OF DISCHARGED
BATTERY.
CAUTION: Keep jumper leads away from moving
parts, pulleys, drive belts and fan blade
assembly.If the booster battery is installed in another vehicle,
start engine and allow to idle.
Start engine of vehicle with discharged battery,
following starting procedure in Owners' Handbook.
CAUTION: If vehicle fails to start within a
maximum time of 12 seconds, switch ignition off
and investigate cause. Failure to follow this
instruction could result in irreparable damage to
catalyst.
To disconnect:
l Remove negative (-) jumper cable from the
engine and then terminal of booster battery.
lRemove positive (+) jumper cable from positive
terminals of booster battery and discharged
battery.

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
09-1
CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
Capacities
The following capacities are only an approximation of
the amount of fluid required to fill the respective
system.
Capacities – UK/ROW
† An extra 420 cc (0.73 imp pt) is required for
vehicles with an air blast fluid cooler fitted.
* Refill capacity is approx. 0.7 litre (1.125 imp. pt)
less than the from dry figures.
Capacities – NAS
Component / system Capacity
Fuel tank:
Td4 Model
K1.8 and KV6 Models
⇒ Up to 03 Model Year
⇒ From 03 Model Year
KV6 Model
⇒ Up to 03 Model Year
⇒ From 03 Model Year59 litres (13 gallons)
59 litres (13 gallons)
64 litres (14.3 gallons)
59 litres (13 gallons)
64 litres (14.3 gallons)
Engine - Td4 (including oil cooler and oil filter):
⇒ Refill 6.8 litres (12 imp. pts)
⇒ Fill from dry 7.3 litres (12.9 imp. pts)
Engine - K1.8 (including filter):
⇒ Refill 4.5 litres (7.9 imp. pts)
⇒ Fill from dry 4.8 litres (8.4 imp. pts)
Engine - KV6 (including oil cooler and filter):
⇒ Refill 5.2 litres (9.125 imp. pts)
⇒ Fill from dry 6.0 litres (10.625 imp. pts)
Manual gearbox - PG1:
⇒ Refill 2.0 litres (3.5 imp. pts)
⇒ From dry 2.2 litres (3.9 imp. pts)
Manual gearbox - Getrag:
⇒ Refill 1.6 litres (2.875 imp. pts)
⇒ From dry 1.67 litres (3 imp. pts)
Automatic gearbox - JATCO:
⇒ Refill 4.0 litres (7 imp. pts)
⇒ From dry
†8.5 litres (15 imp. pts)
Intermediate Reduction
Drive1.1 litres (2 imp. pts)
Rear differential:
⇒ Maximum 830 ml (29.2 imp. fl. oz.)
⇒ Minimum 750 ml (26.4 imp. fl. oz.)
Power steering reservoir 335 cm
3
Cooling system - Td4 Engine – Fill from dry (with
reservoir)*:
⇒ Automatic - Up to 03
Model Year
⇒ Automatic - From 03
Model Year7.25 litres (12.8 imp. pts)
7.35 litres (13 imp. pts)
⇒ Manual 7.25 litres (12.8 imp. pts)
Cooling system - K1.8 Engine:
⇒ Fill from dry (with
reservoir)*5.8 litres (10.25 imp. pts)
Cooling system - KV6 Engine:
⇒ Fill from dry (with
reservoir)*7.8 litres (13.75 imp. pts)
Reservoir tank:
⇒ Maximum fill 0.44 litres (0.75 imp. pts)
⇒ Expansion tank volume 1.2 litres (2.125 imp. pts)
⇒ Gross expansion
capacity0.72 litres (1.27 imp. pts)
Windscreen washer
reservoir 4.0 litres (7 imp. pints)
Component / system Capacity
Fuel tank:
⇒ Up to 02.5 Model Year
⇒ From 02.5 Model Year15.6 US gallons
17.2 US gallons
Engine - KV6 (including oil cooler and filter):
⇒ Engine oil and filter
change11 US pts
⇒ Fill from dry 12.7 US pts
Automatic gearbox - JATCO:
⇒ Refill 8.5 US pts
⇒ From dry 18.2 US pts
Intermediate Reduction
Drive2.3 US pts
Rear differential:
⇒ Maximum
⇒ Minimum28.1 US fl. oz.
25.4 US fl. oz.
Power steering reservoir 335 cm
3
Cooling system - KV6 Engine:
⇒ Fill from dry (with
reservoir)17.82 US pts
Reservoir tank:
⇒ Maximum fill 0.93 US pts
⇒ Expansion tank volume 2.54 US pts
⇒ Gross expansion
capacity1.52 US pts
Windscreen washer
reservoir 8.5 US pts Component / system Capacity

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
09-3
Lubrication
The engine and other lubricating systems are filled
with high- performance lubricants giving prolonged
life.
CAUTION: Always use a high quality oil of the
correct viscosity range in the engine. The use of
oil of the incorrect specification can lead to high
oil and fuel consumption and ultimately to
damaged components.
Oil to the correct specification contains additives
which disperse the corrosive acids formed by
combustion and prevent the formation of sludge
which can block the oil ways. Additional oil additives
should not be used.
Always adhere to the recommended servicing
intervals.
Engine oil
Engine oil viscosity / temperature ranges are
indicated in the following table:
a0W/30; 5W/30
b0W/40, 50, 60; 5W/40, 50, 60
c10W/30
d10W/40, 50, 60
Engine oil – Td4 engine
Use 0W/30 or 5W/40, 50, 10W/30, 40, 60 oil meeting
ACEA A3/B3 specifications, and having a viscosity
band recommended for the temperature range of
your locality. Where oils to these European
specifications are not available, well known brands of
oils meeting API SH quality should be used.Engine oil – K1.8 engine
Use a 10W/40 oil meeting specification ACEA A2 or
A3.
Engine oil – KV6 engine – Non NAS models
Use a 10W/40 oil meeting specification ACEA A2 or
A3.
Engine oil – KV6 engine - NAS models
Use a 5W/40 fully synthetic oil meeting specification
ACEA A3. Where oils to these European
specifications are not available, well known brands of
oils meeting API SH quality should be used.
Gearbox oil
Use of gearbox oils other than those specified may
result in serious damage to the gearbox.
Manual Gearbox – PG1 and Getrag
Use OPEL B 0400063 for refill or topping-up.
Automatic Gearbox – JATCO
Use Texaco N402 fluid for refill or topping-up.
Intermediate Reduction Drive
Texaco S5 75W90; Synthetic oil or equivalent,
meeting: API GL5
Rear Differential
Multigear 80W/90 ETL; Specification: API GL5
Gear linkage - Manual
Use grease containing 3% Molybdenum Disulphide.
General Greasing
Use Multipurpose Lithium Base Grease NLGI
consistency No. 2.
Bonnet latch
Lubricate cable and latch with oil.