2001 LAND ROVER FREELANDER exhaust

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
6CONTENTS
EMISSION CONTROL ............................................................................. 17-1-1
ADJUSTMENTS
Evaporative loss control system (EVAPS) - leak test - NAS........................................................... 17-1-1
REPAIRS
Valve - depression limiter - Td4 ..................................................................................................... 17-1-3
Solenoid - canister purge - KV6 ...................................................................................................... 17-1-4
Charcoal canister - petrol - Non NAS ............................................................................................. 17-1-4
Charcoal canister - NAS ................................................................................................................. 17-1-5
Valve - canister purge - K1.8 .......................................................................................................... 17-1-6
Valve - EGR - Td4 .......................................................................................................................... 17-1-7
Solenoid/modulator valve - EGR - Td4 ........................................................................................... 17-1-8
Thermal valve - exhaust gas recirculation (EGR) -
Td4 Automatic transmission (hot climates) - from 03 MY ............................................................... 17-1-9
Cooler - EGR - Td4 ......................................................................................................................... 17-1-9
Module - tank leakage diagnostic (DMTL) ...................................................................................... 17-1-11
Filter - fuel leak detection pump - KV6 - NAS ................................................................................ 17-1-12
Catalytic converter - RH - KV6 - NAS ............................................................................................ 17-1-12
ENGINE MANAGEMENT SYSTEM - SIEMENS....................................... 18-3-1
REPAIRS
Spark plugs - up to 03MY ............................................................................................................... 18-3-1
Spark plugs - from 03MY ................................................................................................................ 18-3-2
Coil - each - LH bank - up to 03MY ................................................................................................ 18-3-3
Coil - each - LH bank - from 03MY ................................................................................................. 18-3-3
Coil - each - RH bank - up to 03MY ................................................................................................ 18-3-4
Coil - each - RH bank - from 03MY................................................................................................. 18-3-4
Engine control module (ECM) - Non NAS ..................................................................................... 18-3-5
Engine control module (ECM) - fuel - NAS .................................................................................... 18-3-6
Idle Air Control Valve (IACV) ......................................................................................................... 18-3-7
Sensor - intake air temperature (IAT) - NAS .................................................................................. 18-3-8
Sensor - engine coolant temperature (ECT) .................................................................................. 18-3-8
Sensor - crankshaft position (CKP) ............................................................................................... 18-3-9
Sensor - throttle position (TP) ......................................................................................................... 18-3-10
Sensor - thermostat monitoring (TM) - KV6 - NAS ........................................................................ 18-3-11
Sensor - camshaft position (CMP) ................................................................................................. 18-3-12
Sensor - knock (KS) ....................................................................................................................... 18-3-13
Switch - throttle pedal - Non NAS ................................................................................................... 18-3-13
Sensor - combined - manifold absolute pressure/Intake air temperature (MAP/IAT) ..................... 18-3-14
Sensor - throttle position (TP) - NAS - up to 03MY......................................................................... 18-3-15
Sensor - throttle position (TP) - NAS - from 03MY ......................................................................... 18-3-16

CONTENTS
8CONTENTS
COOLING SYSTEM - K SERIES KV6 ...................................................... 26-3-1
ADJUSTMENTS
Coolant - drain and refill.................................................................................................................. 26-3-1
REPAIRS
Cooling fan and motor ................................................................................................................... 26-3-3
Control unit - radiator cooling fan - 2002 MY On ............................................................................ 26-3-3
Radiator assembly ......................................................................................................................... 26-3-4
Thermostat ..................................................................................................................................... 26-3-6
Coolant pump ................................................................................................................................. 26-3-7
MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6 ......................... 30-3-1
REPAIRS
Front pipe - Non NAS ..................................................................................................................... 30-3-1
Front pipe - NAS ............................................................................................................................ 30-3-3
Intermediate pipe - Non NAS .......................................................................................................... 30-3-4
Intermediate pipe - NAS ................................................................................................................ 30-3-5
Tail pipe & silencer ......................................................................................................................... 30-3-6
Heat shield - A/C compressor - KV6 - NAS .................................................................................... 30-3-7
Gasket - inlet manifold - LH ............................................................................................................ 30-3-8
Gasket - exhaust manifold - RH - Non NAS ................................................................................... 30-3-9
Gasket(s) - exhaust manifold - RH - KV6 - NAS ............................................................................ 30-3-10
Gasket - exhaust manifold - LH - Non NAS .................................................................................... 30-3-11
Gasket(s) - exhaust manifold - LH - NAS ....................................................................................... 30-3-12
Seals - inlet manifold chamber - up to 03MY .................................................................................. 30-3-13
Seals - inlet manifold chamber - from 03MY................................................................................... 30-3-18
Gasket - inlet manifold - RH............................................................................................................ 30-3-23
OVERHAUL
Seals - manifold chamber - up to 03MY ........................................................................................ 30-3-25
Seals - manifold chamber - from 03MY ......................................................................................... 30-3-27
INTERMEDIATE REDUCTION DRIVE ..................................................... 41-1
ADJUSTMENTS
Intermediate reduction drive (IRD) fluid - drain & refill - Non NAS.................................................. 41-1
Intermediate reduction drive (IRD) lubrication system - drain & refill - NAS .................................. 41-2
REPAIRS
Intermediate reduction drive (IRD) unit - Td4 ................................................................................. 41-3
Intermediate reduction drive (IRD) unit - K1.8 ................................................................................ 41-7
Intermediate reduction drive (IRD) unit - KV6 ................................................................................. 41-10
Gasket - end cover - IRD housing - Td4 ........................................................................................ 41-14
Gasket - end cover - IRD housing - KV6 ...................................................................................... 41-15
Gasket - end cover - IRD housing - K1.8 ....................................................................................... 41-18
Seals - primary gear shaft ............................................................................................................. 41-19
Seal - pinion gear .......................................................................................................................... 41-21
Seal - driveshaft - LH - Td4 & KV6 models ..................................................................................... 41-23
Seal - drive shaft - LH - K1.8 .......................................................................................................... 41-24
Seal - driveshaft - RH .................................................................................................................... 41-25
Seal - pinion gear housing - Td4..................................................................................................... 41-25
Seal - pinion gear housing - K1.8 ................................................................................................... 41-27
Seal - pinion gear housing - KV6 - Non NAS .................................................................................. 41-28
Seal - pinion gear housing - KV6 - NAS ........................................................................................ 41-30

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

GENERAL INFORMATION
03-3
Brake hydraulics
Observe the following recommendations when
working on the brake system:
lAlways use two spanners when loosening or
tightening brake pipe or hose connections.
lEnsure that hoses run in a natural curve and are
not kinked or twisted.
lFit brake pipes securely in their retaining clips
and ensure that the pipe run cannot contact a
potential chafing point.
lContainers used for hydraulic brake fluid must
be kept absolutely clean.
lDo not store hydraulic brake fluid in an unsealed
container, it will absorb water and in this
condition would be dangerous to use due to a
lowering of its boiling point.
lDo not allow hydraulic brake fluid to be
contaminated with mineral oil, or put new
hydraulic brake fluid in a container which has
previously contained mineral oil.
lDo not re-use hydraulic brake fluid previously
removed from the system.
lAlways use clean brake fluid or a recommended
alternative to clean hydraulic components.
lFit a blanking cap to a hydraulic union and a
plug to its socket, immediately after
disconnection of pipes and hoses to prevent the
ingress of dirt.
lAbsolute cleanliness must be observed when
working with hydraulic components.
lIt is imperative that the correct brake fittings are
used and that threads of components are
compatible.
Cooling system caps and plugs
Extreme care is necessary when removing engine
cooling system expansion tank caps and coolant
drain or bleed screws when the engine is hot, and
especially if it is overheated.
To avoid the possibility of scalding allow the engine
to cool before attempting coolant cap or plug
removal.
Environmental Precautions
General
This section provides general information which can
help to reduce adverse environmental impacts
incurred through the activities carried out in
workshops.
Emissions to air
Many of the activities that are carried out in
workshops emit gases and fumes which contribute to
global warming, depletion of the ozone layer and/or
the formation of photo-chemical smog at ground
level. By considering and controlling how the
workshop activities are carried out, these gases and
fumes can be minimised, thus reducing the damage
to the environment.
Exhaust fumes
Running car engines is an essential part of workshop
activities and exhaust fumes need to be ventilated to
atmosphere. However, the amount of time engines
are running and the position of the vehicle should be
carefully considered at all times, to reduce the
release of poisonous gases and minimise the
inconvenience to people living nearby.
Solvents
Some of the cleaning agents used are solvent based
and will evaporate to atmosphere if used carelessly,
or if cans are left unsealed. All solvent containers
should be firmly closed when not needed and solvent
should be used sparingly. Suitable alternative
materials may be available to replace some of the
commonly used solvents. Similarly, many paints are
solvent based and the spray should be minimised to
reduce solvent emissions.
Refrigerant
It is illegal to release any refrigerants into the
atmosphere. Discharge and replacement of these
materials from air conditioning units should only be
carried out using the correct equipment.
Checklist
Always adhere to the following:
Engines –
ldon't leave engines running unnecessarily;
lminimise testing times and check where the
exhaust fumes are being blown.

GENERAL INFORMATION
03-5
Local issues
A number of environmental issues will be of
particular concern to residents and other neighbours
close to the site. The sensitivity of these issues will
depend on the proximity of the site and the layout
and amount of activity carried on at the site.
Noise is a major concern and therefore consideration
should be given to the time spent carrying out noisy
activities and the location of those activities that can
cause excessive noise.
Car alarm testing, panel beating, hammering and
other such noisy activities should, whenever
possible, be carried out indoors with doors and
windows shut, or as far away from houses as
possible.
Running vehicle engines may be an outside activity
which could cause nuisance to neighbours because
of both noise and smell.
Be sensitive to the time of day when these activities
are carried out and minimise the time of the noisy
operation, particularly in the early morning and late
evening.
Another local concern will be the smell from the
various materials used. Using less solvent, paint and
petrol could help prevent this annoyance.
Local residents and other business users will also be
concerned about traffic congestion, noise and
exhaust fumes, be sensitive to these concerns and
try to minimise inconvenience from deliveries,
customers and servicing operations.
Checklist
Always adhere to the following:
lidentify where the neighbours who are likely to
be affected are situated;
lminimise noise, smells and traffic nuisance;
lprevent litter by putting waste in the correct
containers;
lhave waste skips emptied regularly.Use of resource
Another environmental concern is the waste of
materials and energy that can occur in day to day
activities.
Electricity for heating, lighting and compressed air
uses resources and releases pollution during its
generation.
Fuel used for heating, running cars or vans and
mobile plant is another limited resource which
consumes large amounts of energy during its
extraction and refining processes.
Water has to be cleaned, piped to site and disposed
of, all of which creates more potential pollution;
Oil, spares, paint etc., have all produced pollution in
the process of manufacture and they become a
waste disposal problem if discarded.
Checklist
Always adhere to the following:
Electricity and heating –
lkeep doors and windows closed in the winter;
lswitch off machinery or lights when not needed;
luse energy efficient heating systems;
lswitch off computers and photocopiers when
not needed.
Fuel –
ldon't run engines unnecessarily;
lthink about whether journeys are necessary and
drive to conserve fuel.
Water –
ldon't leave taps and hose pipes running;
lmend leaks quickly, don't be wasteful.
Compressed air –
ldon't leave valves open;
lmend leaks quickly;
ldon't leave the compressor running when not
needed.
Use of environmentally damaging materials –
lcheck whether a less toxic material is available.
Handling and storage of materials –
lhave the correct facilities available for handling
liquids to prevent spillage and wastage as listed
above;
lprovide suitable locations for storage to prevent
frost damage or other deterioration.

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