2001 LAND ROVER FREELANDER drive belt

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
10 CONTENTS
REAR AXLE & FINAL DRIVE ................................................................... 51-1
REPAIRS
Differential assembly ..................................................................................................................... 51-1
Cover - rear - differential ................................................................................................................. 51-2
Bush - differential mounting - front ................................................................................................. 51-3
Bush - differential mounting - rear ................................................................................................. 51-4
Oil seal - pinion .............................................................................................................................. 51-5
Oil seal - differential housing ......................................................................................................... 51-6
STEERING ................................................................................................ 57-1
ADJUSTMENTS
Power assisted steering (PAS) system - bleed............................................................................... 57-1
Cable - key interlock - adjust .......................................................................................................... 57-1
Front wheel alignment - check & adjust .......................................................................................... 57-2
Alignment - rear wheel - check & adjust ......................................................................................... 57-3
Power steering - pressure test ........................................................................................................ 57-4
REPAIRS
Power steering rack ........................................................................................................................ 57-5
Gaiter - PAS rack ............................................................................................................................ 57-8
Oil cooler - Td4 & K1.8 models ....................................................................................................... 57-9
Oil cooler - KV6 models .................................................................................................................. 57-10
Drive belt - K1.8 .............................................................................................................................. 57-11
Pump - steering - KV6 .................................................................................................................... 57-12
Pump - steering - K1.8 .................................................................................................................... 57-14
Pump - steering - Td4 ..................................................................................................................... 57-15
Nacelle - column ............................................................................................................................. 57-16
Column lock & ignition/starter switch assembly .............................................................................. 57-17
Cable - key interlock ....................................................................................................................... 57-18
Column assembly - inner & outer ................................................................................................... 57-19
Ball joint - track rod ......................................................................................................................... 57-23
Track rod......................................................................................................................................... 57-24
Steering wheel ................................................................................................................................ 57-25
FRONT SUSPENSION .............................................................................. 60-1
REPAIRS
Anti roll bar...................................................................................................................................... 60-1
Ball joint link - anti roll bar .............................................................................................................. 60-2
Mounting rubbers - anti roll bar - set .............................................................................................. 60-2
Bearing - hub ................................................................................................................................. 60-3
Damper .......................................................................................................................................... 60-7
Lower arm assembly ...................................................................................................................... 60-10
Rear beam ..................................................................................................................................... 60-13
Bush - lower arm - front .................................................................................................................. 60-15
Bush - lower arm - rear ................................................................................................................... 60-16

CONTENTS
18 CONTENTS
HEATING AND VENTILATION ................................................................. 80-1
REPAIRS
Controls - heater - up to 04MY ....................................................................................................... 80-1
Controls - heater - from 04MY ........................................................................................................ 80-2
Servo - air recirculation .................................................................................................................. 80-3
Switch - recirculation control .......................................................................................................... 80-3
Switch - fan - front heater .............................................................................................................. 80-4
Ventilator - face level - LH ............................................................................................................. 80-5
Plenum - air intake ......................................................................................................................... 80-6
Heater unit ..................................................................................................................................... 80-7
Element - positive temperature co-efficient (PTC) heater - Td4 models......................................... 80-10
Harness - positive temperature co-efficient (PTC) heater - Td4 models ........................................ 80-11
Microswitch - positive temperature co-efficient (PTC) heater - Td4 models ................................... 80-14
Blower assembly ............................................................................................................................ 80-14
Resistor unit - fan motor ................................................................................................................ 80-15
Matrix - heater................................................................................................................................. 80-15
Relay - power - positive temperature co-efficient (PTC) - Td4 models ........................................... 80-16
Relay - control - positive temperature co-efficient (PTC) - Td4 models .......................................... 80-17
Fuel burning heater (FBH) .............................................................................................................. 80-18
Sensor - outside temperature (OT) ................................................................................................. 80-19
Fuel pump - fuel burning heater - up to 03MY ................................................................................ 80-20
Fuel pump - fuel burning heater - from 03MY ................................................................................. 80-21
AIR CONDITIONING ................................................................................. 82-1
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING
Refrigerant recovery - recycling and recharge................................................................................ 82-1
ADJUSTMENTS
Drive belt - compressor - Td4 ......................................................................................................... 82-3
REPAIRS
Drive belt - compressor - Td4 ......................................................................................................... 82-5
Compressor - Td4 ........................................................................................................................... 82-6
Compressor - KV6 .......................................................................................................................... 82-7
Compressor - K1.8.......................................................................................................................... 82-8
Condenser ...................................................................................................................................... 82-10
Receiver drier ................................................................................................................................. 82-12
Switch - control ............................................................................................................................... 82-13
Sensor - refrigerant pressure .......................................................................................................... 82-14
Valve - thermostatic expansion (TXV) ............................................................................................ 82-15
Evaporator ..................................................................................................................................... 82-16

CONTENTS
CONTENTS 19
WIPERS AND WASHERS ........................................................................ 84-1
REPAIRS
Reservoir - washer ......................................................................................................................... 84-1
Jet - washer - each ........................................................................................................................ 84-2
Pump - washer ............................................................................................................................... 84-2
Arm - wiper - each .......................................................................................................................... 84-3
Blade - wiper - each ....................................................................................................................... 84-3
Motor & linkage - wiper .................................................................................................................. 84-4
Switch - wiper/washer .................................................................................................................... 84-4
Pump - washer ............................................................................................................................... 84-5
Arm - wiper ..................................................................................................................................... 84-5
Blade - wiper .................................................................................................................................. 84-6
Motor - wiper .................................................................................................................................. 84-7
Switch - combined wiper/washer ................................................................................................... 84-8
Relay - tailgate wipe - 5 door ......................................................................................................... 84-8
CHARGING AND STARTING ................................................................... 86-1-1
ADJUSTMENTS
Ancillary drive belt - K1.8 ............................................................................................................... 86-1-1
Ancillary drive belt - K1.8 with A/C .................................................................................................. 86-1-2
REPAIRS
Alternator - Td4 ............................................................................................................................... 86-1-3
Alternator - KV6 .............................................................................................................................. 86-1-5
Alternator - K1.8 .............................................................................................................................. 86-1-6
Ancillary drive belt - Td4 ................................................................................................................. 86-1-7
Ancillary drive belt - K1.8 without A/C ............................................................................................. 86-1-8
Ancillary drive belt - K1.8 with A/C .................................................................................................. 86-1-9
Ancillary drive belt - KV6 ................................................................................................................. 86-1-10
Tensioner - ancillary drive belt - Td4 ............................................................................................... 86-1-11
Battery ............................................................................................................................................. 86-1-12
Carrier - battery ............................................................................................................................... 86-1-13
Relay - main .................................................................................................................................... 86-1-14
Starter motor - Td4 .......................................................................................................................... 86-1-15
Starter motor - KV6 ......................................................................................................................... 86-1-16
Starter motor - K1.8 ........................................................................................................................ 86-1-17
Relay - starter ................................................................................................................................. 86-1-18

GENERAL INFORMATION
03-26
Rotary coupler
A - Refer to the Workshop Manual for detailed
instructions.B - Ensure wheels are in the straight
ahead position before removal and refitting.C -
LAND ROVER Part Number/Bar code - The code
must be recorded and quoted for ordering purposes.
Front seat belt pre-tensioners
A warning label is fixed to the piston tube of the front
seat belt pre-tensioners:
lExercise caution.
lRefer to the publication where the procedures,
instructions and advice can be found (usually
Workshop Manual or Owner's Handbook) for
working on SRS system components.
lDo not attempt to repair or disassemble.Bar codes
Driver's airbag module
Bar codes are fitted to SRS system components and
components which are critically related to SRS
operation. The code number(s) must be recorded if
the component is to be replaced. Components
featuring bar codes include the following:
lDriver's front airbag module – label attached to
rear of module housing.
lPassenger front airbag module – label attached
to rear of module housing.
lRotary coupler – label attached on face of rotary
coupler.
lDCU – included on label on top of DCU.
lSRS wiring – label attached around harness
wires.
VEHICLE RECOVERY
Observe the following procedures for vehicle towing
after a collision has taken place:
Towing – SRS components not deployed
Normal towing procedures are unlikely to cause an
SRS module to deploy. However, as a precaution,
switch the ignition off and then disconnect both
battery leads. Disconnect the negative '-' lead first.
Towing – SRS components deployed
Once the driver's airbag has been deployed, the
vehicle must have a front suspended tow. However,
as a precaution, switch the ignition off and then
disconnect both battery leads. Disconnect the
negative '-' lead first.

GENERAL INFORMATION
03-28
SRS component replacement policy
The following information details the policy for
replacement of SRS components; either as a result
of a vehicle accident or as a result of vehicle age.
Impacts which do not deploy the airbags or seat
belt pre-tensioners
Check for structural damage in the area of the
impact, paying particular attention to bumper
armatures, longitudinals, crash cans and bracketry.
Impacts which deploy the airbags and/or seat
belt pre-tensioners
The inspection and replacement policy is dependent
on the type and severity of the crash condition. The
following guidelines are the minimum that should be
exercised as a result of the deployment of specific
SRS components.
Front airbag/ seat belt pre-tensioner deployment
(driver and passenger)
If the front airbags and/or seat belt pre-tensioners are
deployed as a result of a front, front angled or side
impact, the following parts must be replaced:
lDriver airbag module
lPassenger airbag module (where fitted)
lSRS flyleads
lSRS DCU
lRotary coupler
lFront seat belt pre-tensioners
In addition, the following should be inspected for
damage and replaced as necessary:
lFront seat belt and buckle tongue (anchorage
points, webbing etc.)
lFascia moulding adjacent to passenger airbag
module (where fitted)
lSteering wheel (if damage is evident)
lFront seat frames and head restraints (if there is
evidence of damage to the seat frame or
cushion pan)
lSteering column (if adjustment is lost or there
are signs of collapse)
lFront seat belt height adjusters on 'BC' posts (5
door models only)
lRear seat belts and seat belt buckles (webbing,
buckle covers, body anchorage and tongue
latching function)Rear Impact
If the seat belt pre-tensioners are deployed during a
rear impact, the following components must be
replaced:
lSeat belt pre-tensioners
lFront and rear automatic seat belt assemblies
used during an impact.
lSRS DCU
In addition, the following components should be
inspected for damage and replaced as necessary:
lFront seat frames
lFront seat belts and buckle (retractors,
webbing, tongue latching, buckle covers, body
anchorages and 'D' loops)
lSeat belt height adjusters (5 door models only)
lRear seat belts and seat belt buckles (webbing,
buckle covers, body anchorage and tongue
latching function)
Periodic replacement of SRS components
The performance of the propellants within airbags
and seat belt pre-tensioners will deteriorate over a
period of time. As a result, it is essential that the
airbags and seat belt pre-tensioners are periodically
replaced to maintain occupant safety. Airbags, seat
belt pre-tensioners and the rotary coupler should be
replaced at the recommended intervals.

GENERAL DATA
04-8
Pistons
Type Aluminium alloy, tin plated, thermal expansion with offset gudgeon pin
Piston diameter:
⇒ Grade A 79.975 - 79.990 mm (3.1486 - 3.1492 in.)
⇒ Grade B 79.991 - 80.005 mm (3.1492 - 3.1498 in.)
Clearance in bore 0.01 - 0.04 mm (0.0004 - 0.0016 in.)
Maximum ovality 0.30 mm (0.012 in.)
Piston rings:
Type: 2 compression, 1 oil control
⇒ Top compression ring Barrel faced, granulite coated
⇒ 2nd compression ring Tapered, phosphate coated
⇒ Oil control ring Nitrided ring with radii and spring
New ring to groove clearance:
⇒ Top compression ring 0.040 - 0.072 mm (0.0016 - 0.0028 in.)
⇒ 2nd compression ring 0.030 - 0.062 mm (0.0012 - 0.0024 in.)
⇒ Oil control ring 0.010 - 0.180 mm (0.0004 - 0.0071 in.)
Ring fitted gap 20 mm (0.75 in) from top of bore:
⇒ Top compression ring 0.20 - 0.35 mm (0.008 - 0.014 in.)
⇒ 2nd compression ring 0.28 - 0.48 mm (0.011 - 0.019 in.)
⇒ Oil control ring 0.15 - 0.40 mm (0.006 - 0.016 in.)
Piston ring width:
⇒ Top compression ring 0.978 - 0.990 mm (0.0385 - 0.0390 in.)
⇒ 2nd compression ring 1.178 - 1.190 mm (0.0464 - 0.0469 in.)
⇒ Oil control ring 0.33 - 0.38 mm (0.0130 - 0.0150 in.)
Camshaft
Type DOHC acting directly on tappets, incorporates target/reluctor for
camshaft sensor
Bearings 6 per camshaft, direct line bored
Drive Toothed belt driven from crankshaft gear, automatically tensioned
Camshaft end-float 0.06 - 0.19 mm (0.002 - 0.007 in.)
⇒ Service limit 0.30 mm (0.012 in.)
Bearing clearance 0.060 - 0.094 mm (0.0024 - 0.0037 in.)
⇒ Service limit 0.15 mm (0.006 in.)
Tappets
Type Self-adjusting lightweight hydraulic tappets, operated directly from
camshafts
Tappet outside diameter 32.959 - 32.975 mm (1.2976 - 1.2982 in.)
Valve timing:
Inlet valves:
⇒ Opens
⇒ Closes
⇒ Maximum lift12° BTDC
52° ABDC
8.8 mm (0.35 in.)
Exhaust valves:
⇒ Opens
⇒ Closes
⇒ Maximum lift52° BBDC
12° ATDC
8.8 mm (0.35 in.) General