2001 LAND ROVER FREELANDER brake

CONTENTS
2CONTENTS
GENERAL DATA ..................................................................................... 04-1
Engine - Td4 Diesel ........................................................................................................................ 04-1
Engine - K1.8 Petrol........................................................................................................................ 04-6
Engine - KV6 Petrol ........................................................................................................................ 04-11
Fuel system - Td4 Diesel ................................................................................................................ 04-16
Fuel system - K1.8 Petrol ............................................................................................................... 04-18
Fuel system - KV6 Petrol ................................................................................................................ 04-18
Cooling system - Td4 Diesel ........................................................................................................... 04-19
Cooling system - K1.8 Petrol .......................................................................................................... 04-19
Cooling system - KV6 Petrol ........................................................................................................... 04-19
Clutch.............................................................................................................................................. 04-20
Manual Gearbox - Getrag ............................................................................................................... 04-21
Manual Gearbox - PG1 ................................................................................................................... 04-22
Intermediate Reduction Drive (IRD)................................................................................................ 04-24
Automatic Gearbox - Jatco ............................................................................................................. 04-25
Rear Axle and Final Drive ............................................................................................................... 04-26
Steering .......................................................................................................................................... 04-27
Front Suspension............................................................................................................................ 04-28
Rear Suspension ............................................................................................................................ 04-30
Brakes............................................................................................................................................. 04-31
Wheels and tyres ............................................................................................................................ 04-32
Tyre pressures ................................................................................................................................ 04-32
Heating and Ventilation................................................................................................................... 04-33
Air Conditioning .............................................................................................................................. 04-33
Electrical - Td4 engine .................................................................................................................... 04-34
Electrical - K1.8 engine ................................................................................................................... 04-34
Electrical - KV6 engine ................................................................................................................... 04-34
Dimensions ..................................................................................................................................... 04-35
Weights ........................................................................................................................................... 04-36
IDENTIFICATION NUMBERS .................................................................. 05-1
Vehicle Identification Number ......................................................................................................... 05-1
Identification Number Locations ..................................................................................................... 05-2

CONTENTS
CONTENTS 3
TORQUE WRENCH SETTINGS .............................................................. 06-1
Maintenance ................................................................................................................................... 06-1
Engine – Td4................................................................................................................................... 06-2
Engine – K1.8 ................................................................................................................................. 06-4
Engine – KV6 .................................................................................................................................. 06-6
Emission Control ............................................................................................................................. 06-8
Engine Management System – EDC .............................................................................................. 06-9
Engine Management System – MEMS ........................................................................................... 06-10
Engine Management System – Siemens ........................................................................................ 06-11
Fuel Delivery System – Diesel ........................................................................................................ 06-12
Fuel delivery system – Petrol .......................................................................................................... 06-13
Cooling System – Td4..................................................................................................................... 06-14
Cooling System – K1.8 ................................................................................................................... 06-14
Cooling System – KV6 .................................................................................................................... 06-14
Manifolds and Exhaust System – Td4 ............................................................................................ 06-15
Manifolds and Exhaust Systems – K1.8 ......................................................................................... 06-16
Manifolds and Exhaust Systems – KV6 .......................................................................................... 06-17
Clutch .............................................................................................................................................. 06-18
Manual Gearbox – PG1 .................................................................................................................. 06-19
Manual Gearbox – Getrag .............................................................................................................. 06-20
Intermediate Reduction Drive ......................................................................................................... 06-21
Automatic Gearbox – Jatco ............................................................................................................. 06-22
Driveshafts ...................................................................................................................................... 06-23
Rear Axles and Final Drive ............................................................................................................. 06-24
Steering........................................................................................................................................... 06-25
Front Suspension and Subframe .................................................................................................... 06-26
Rear Suspension and Subframe ..................................................................................................... 06-27
Brakes ............................................................................................................................................. 06-28
Supplementary Restraint Systems .................................................................................................. 06-29
Body ................................................................................................................................................ 06-30
Heating and Ventilation ................................................................................................................... 06-32
Air Conditioning............................................................................................................................... 06-33
Wipers and Washers ....................................................................................................................... 06-34
Electrical ......................................................................................................................................... 06-35
LIFTING AND TOWING ........................................................................... 08-1
Jacking ............................................................................................................................................ 08-1
Towing ............................................................................................................................................ 08-2
Emergency starting ......................................................................................................................... 08-4
CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS ...................... 09-1
Capacities ....................................................................................................................................... 09-1
Fluids .............................................................................................................................................. 09-2
Lubrication ...................................................................................................................................... 09-3
Sealants .......................................................................................................................................... 09-4

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 11
REAR SUSPENSION ................................................................................ 64-1
REPAIRS
Bush - trailing link............................................................................................................................ 64-1
Bearing - hub ................................................................................................................................. 64-2
Damper .......................................................................................................................................... 64-5
Trailing arm .................................................................................................................................... 64-8
Bush - trailing arm .......................................................................................................................... 64-9
Link - adjustable - transverse ......................................................................................................... 64-10
Link - transverse fixed .................................................................................................................... 64-11
Bush - link - transverse .................................................................................................................. 64-12
Sub frame ...................................................................................................................................... 64-13
BRAKES ................................................................................................... 70-1
ADJUSTMENTS
Brake bleed ..................................................................................................................................... 70-1
Cable - handbrake - check and adjust ............................................................................................ 70-2
REPAIRS
Drum - rear ...................................................................................................................................... 70-3
Disc - front....................................................................................................................................... 70-5
Hose - front - primary - LH .............................................................................................................. 70-6
Hose - rear ...................................................................................................................................... 70-7
Cylinder - master - tandem - LHD ................................................................................................... 70-8
Cylinder - master - tandem - RHD................................................................................................... 70-9
Lever assembly - handbrake........................................................................................................... 70-10
Cable - handbrake ......................................................................................................................... 70-11
Switch - handbrake warning ............................................................................................................ 70-12
Switch - stop light ............................................................................................................................ 70-13
Sensor - brake pedal position ........................................................................................................ 70-13
Shoes/pads - front - set................................................................................................................... 70-14
Brake Shoes - rear set .................................................................................................................... 70-15
Servo assembly - LHD .................................................................................................................... 70-17
Servo assembly - RHD ................................................................................................................... 70-19
Vacuum pump - Td4 - manual ........................................................................................................ 70-20
Vacuum pump - Td4 - automatic ..................................................................................................... 70-21
Vacuum - enhancer - KV6 .............................................................................................................. 70-22
Carrier assembly - calliper - front ................................................................................................... 70-23
Wheel cylinder - rear ....................................................................................................................... 70-24
Switch - low fluid level ..................................................................................................................... 70-25
Sensor & harness - front wheel - RH .............................................................................................. 70-25
Sensor & harness - front wheel - LH ............................................................................................... 70-27
Sensor & harness - rear wheel ....................................................................................................... 70-29
Modulator unit ................................................................................................................................. 70-30
Switch - hill descent - from 04MY ................................................................................................... 70-31
Switch - hill descent - up to 03MY................................................................................................... 70-32

CONTENTS
CONTENTS 21
WINDOWS ................................................................................................ 86-5-1
REPAIRS
Motor & control unit - front door - 3 door ......................................................................................... 86-5-1
Motor & control unit - front door - 5 door ......................................................................................... 86-5-2
Switch - master window - 5 door - from 04MY ................................................................................ 86-5-2
Relay - control - tail door glass ....................................................................................................... 86-5-3
Microswitch - hardtop sensing - 3 door ........................................................................................... 86-5-4
Relay - heated front screen ........................................................................................................... 86-5-5
Switch - backlight heater ................................................................................................................. 86-5-6
IN CAR ENTERTAINMENT ...................................................................... 86-6-1
REPAIRS
Radio - up to 04MY ......................................................................................................................... 86-6-1
Radio/CD - from 04MY .................................................................................................................... 86-6-2
Speaker - rear - 3 door .................................................................................................................... 86-6-3
Speaker - rear - 5 door .................................................................................................................... 86-6-3
Speaker - front ................................................................................................................................ 86-6-4
Aerial - manual - 3 door .................................................................................................................. 86-6-4
Aerial - manual - 5 door .................................................................................................................. 86-6-5
Coaxial lead - front aerial - 3 door ................................................................................................... 86-6-6
Coaxial lead - front aerial - 5 door ................................................................................................... 86-6-7
Speaker - tweeter - front ................................................................................................................. 86-6-8
Speaker - tweeter - rear - 3 door ..................................................................................................... 86-6-9
Amplifier - power ............................................................................................................................ 86-6-10
Sub-woofer assembly .................................................................................................................... 86-6-11
Coaxial lead - extension.................................................................................................................. 86-6-12
HARNESSES ............................................................................................ 86-7-1
REPAIRS
Fuse box - passenger compartment ............................................................................................... 86-7-1
Harness - main ................................................................................................................................ 86-7-2
Harness - tailgate ............................................................................................................................ 86-7-12
Harness - interior lights - 5 door ...................................................................................................... 86-7-15
Harness - front door - 5 door ........................................................................................................... 86-7-15
Harness - rear door ......................................................................................................................... 86-7-16
DRIVER CONTROLS ................................................................................ 86-8-1
REPAIRS
Switch - remote control - audio system .......................................................................................... 86-8-1
Switch - park distance control (PDC) - from 04 MY ........................................................................ 86-8-1
Control unit (ECU) - parking aid - from 04MY ................................................................................. 86-8-2
Sensor - parking aid - rear - from 04MY ......................................................................................... 86-8-2
Sounder - parking aid - rear - from 04MY ....................................................................................... 86-8-3
Switch - handbrake warning ............................................................................................................ 86-8-3
Switch - hazard warning - from 04MY ............................................................................................. 86-8-4
Cigar lighter - front .......................................................................................................................... 86-8-4
Switch - control - exterior mirror ...................................................................................................... 86-8-5

INTRODUCTION
01-3
Abbreviations and Symbols
A Amperes
AAP Ambient Air Pressure
AAT Ambient Air Temperature
ABDC After Bottom Dead Centre
ABS Anti-Lock Brake System
ABS / TC Anti-lock Brake System / Traction
Control
ac Alternating current
A/C Air Conditioning
ACE Active Cornering Enhancement
ACEA Association of Constructors of
European Automobiles
AFR Air Fuel Ratio
AP Ambient Pressure
ASC Anti-shunt Control
ATC Air Temperature Control
ATDC After Top Dead Centre
AUX Auxiliary
AVC Automatic Volume Control
BBDC Before Bottom Dead Centre
BBUS Battery Backed Up Sounder
BCU Body Control Unit
BDC Bottom Dead Centre
bhp Brake Horse Power
BP Boost Pressure
BPP Brake Pedal Position
BS British Standard
BTDC Before Top Dead Centre
BWD Backward
C Celsius
CAN Controller Area Network
CD Compact Disc
CDC Centre Differential Control
CDL Central Door Locking
CD - ROM Compact Disc - Read Only
Memory
CFC Chlorofluorocarbon
CHMSL Centre High Mounted Stop Lamp
CKP Crankshaft Position
CLV Calculated Load Value
cm Centimetre
cm
2Square centimetre
cm3Cubic centimetre
CMP Camshaft Position
CPP Clutch Pedal Position
CO Carbon Monoxide
CO
2Carbon Dioxide
COB Clear Over Base
CR Common Rail
CVS Canister Vent Solenoid
dB Decibels
DDM Driver's Door Module
deg. Degree, angle or temperature
DI Direct Injection
dia. DiameterDIN Deutsche Industrie Normen
(German Industrial Standards)
dc Direct current
DCV Directional Control Valve
DOHC Double Overhead Camshaft
DSP Digital Signal Processing
DTI Dial Test Indicator
DMF Dual Mass Flywheel
DVD Digital Versatile Disc
EACV Electronic Air Control Valve
EAT Electronic Automatic
Transmission
EBD Electronic Brake pressure
Distribution
ECD European Community Directive
ECM Engine Control Module
ECT Engine Coolant Temperature
ECU Electronic Control Unit
EDC Electronic Diesel Control
EEPROM Electronic Erasable
Programmable Read Only
Memory
EGR Exhaust Gas Recirculation
EKA Emergency Key Access
ELR Emergency Locking Retractor
EN European Norm
EOBD European On Board Diagnostics
EON Enhanced Other Network
ERL Electrical Reference Library
ETC Electronic Traction Control
EUI Electronic Unit Injector
EVAP Evaporative Emission
EVR Electronic Vacuum Regulator
F Fahrenheit
ft. Feet
FBH Fuel Burning Heater
FET Field Effect Transistor
FIP Fuel Injection Pump
FTC Fast Throttle Control
FWD Forward
> Greater than
g Gramme or Gravity
gal. Gallons
GMT Greenwich Mean Time
GPS Global Positioning System
hHour
hc High compression
HC Hydro Carbons
HDC Hill Descent Control
HDOP Height Dilation Of Precision
HDPE High Density Polyethylene
HFS Heated Front Screen
Hg Mercury
HO
2S Heated Oxygen Sensor
HMW High Molecular Weight

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.