2001 LAND ROVER FREELANDER fuel filter
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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
Page 9 of 1007
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
Page 10 of 1007
CONTENTS
CONTENTS 7
FUEL DELIVERY SYSTEM - PETROL..................................................... 19-2-1
ADJUSTMENTS
Throttle cable - check and adjust - KV6 ......................................................................................... 19-2-1
Throttle cable - check and adjust - K1.8 ......................................................................................... 19-2-2
Fuel system - depressurise - KV6 - Non NAS ................................................................................. 19-2-2
Fuel system - depressurise - KV6 - NAS ....................................................................................... 19-2-3
Fuel system - depressurise - K1.8 .................................................................................................. 19-2-4
Fuel system - pressure test - KV6 - Non NAS................................................................................. 19-2-4
Fuel system - pressure test - KV6 - NAS ....................................................................................... 19-2-5
Fuel system - pressure test - K1.8 .................................................................................................. 19-2-5
Fuel tank - drain .............................................................................................................................. 19-2-6
REPAIRS
Air cleaner - K1.8 ............................................................................................................................ 19-2-7
Element - air cleaner - K1.8 ............................................................................................................ 19-2-8
Element - air cleaner - KV6 ............................................................................................................. 19-2-8
Element - air cleaner - KV6 - NAS ................................................................................................. 19-2-9
Cable - throttle - KV6 ...................................................................................................................... 19-2-10
Switch - inertia ................................................................................................................................ 19-2-11
Sensor - heated oxygen (H02S) - pre-catalyst - LH - KV6 - Non NAS ............................................ 19-2-12
Sensor - heated oxygen (H02S) - pre-catalyst - LH - KV6 - NAS .................................................. 19-2-13
Sensor - heated oxygen (H02S) - front - K1.8 ................................................................................ 19-2-14
Sensor - heated oxygen (H02S) - pre-catalyst - RH - KV6 - Non NAS ........................................... 19-2-15
Sensor - heated oxygen (H02S) pre-catalyst - RH - KV6 - NAS .................................................... 19-2-16
Sensor - mass air flow (MAF) - NAS .............................................................................................. 19-2-16
Relay - fuel pump ............................................................................................................................ 19-2-17
Throttle housing - K1.8 .................................................................................................................... 19-2-17
Throttle housing - KV6 - Non NAS .................................................................................................. 19-2-19
Throttle housing - KV6 - NAS ......................................................................................................... 19-2-22
Variable induction system (VIS) balance motor - KV6 .................................................................... 19-2-23
Sensor - heated oxygen (H02S) - post catalyst - LH - KV6 - Non NAS .......................................... 19-2-24
Sensor - heated oxygen (H02S) - post catalyst - LH - KV6 - NAS .................................................. 19-2-25
Sensor - heated oxygen (H02S) - post cat - K1.8 ........................................................................... 19-2-26
Sensor - heated oxygen (H02S) - post catalyst - RH - KV6 - NAS ................................................. 19-2-27
Filter - main ..................................................................................................................................... 19-2-28
Pump - fuel ...................................................................................................................................... 19-2-29
Tank - Non NAS .............................................................................................................................. 19-2-30
Tank - NAS ..................................................................................................................................... 19-2-32
Filler neck ........................................................................................................................................ 19-2-34
Fuel rail - KV6 - Non NAS ............................................................................................................... 19-2-35
Fuel rail - KV6 - NAS ...................................................................................................................... 19-2-36
Injector - KV6 .................................................................................................................................. 19-2-38
Injectors - set - K1.8 ........................................................................................................................ 19-2-39
Actuator unit - cruise control - KV6 - non NAS ................................................................................ 19-2-40
Vacuum pump - cruise control - KV6 - non NAS ............................................................................. 19-2-41
Switch - cruise control - KV6 - up to 04MY ..................................................................................... 19-2-41
Switch - engagement (on/off) - from 04MY .................................................................................... 19-2-42
Switch - multi-purpose ................................................................................................................... 19-2-42
ECU - cruise control - KV6 .............................................................................................................. 19-2-43
Interface ECU - cruise control - KV6 ............................................................................................... 19-2-43
Page 37 of 1007
GENERAL INFORMATION
03-6
Waste Management
One of the major ways that pollution can be reduced
is by the careful handling, storage and disposal of all
waste materials that occur on sites. Legislation
makes it illegal to dispose of waste materials other
than to licensed waste carriers and disposal sites.
This means that it is necessary to not only know what
the waste materials are, but also to have the
necessary documentation and licenses.
Handling and storage of waste
Ensure that waste materials are not poured down the
drain or onto soils. They should be stored in such a
way as to prevent the escape of material to land,
water or air.
They must also be segregated into different types of
waste e.g. oil, metals, batteries, used vehicle
components. This will prevent any reaction between
different materials and assist in disposal.
Disposal of waste
Disposal of waste materials must only be to waste
carriers who are licensed to carry those particular
waste materials and all the necessary
documentation must be completed. The waste
carrier is responsible for ensuring that the waste is
taken to the correct disposal sites.Dispose of waste in accordance with the following
guidelines:
lFuel, hydraulic fluid, anti-freeze and oil –
keep separate and dispose of to specialist
contractor.
lRefrigerant – collect using specialist
equipment and containers, and reuse.
lDetergents – safe to pour down the foul drain
if diluted.
lPaint, thinners – keep separate and dispose of
to specialist contractor.
lComponents – send back to supplier for
refurbishment, or disassemble and reuse any
suitable parts. Dispose of the remainder in
ordinary waste.
lSmall parts – reuse any suitable parts, dispose
of the remainder in ordinary waste.
lMetals – can be sold if kept separate from
general waste.
lTyres – keep separate and dispose of to
specialist contractor.
lPackaging – compact as much as possible and
dispose of in ordinary waste.
lAsbestos-containing – keep separate and
dispose of to specialist contractor.
lOily and fuel wastes (e.g. rags, used spill kit
material) – keep separate and dispose of to
specialist contractor.
lAir filters – keep separate and dispose of to
specialist contractor.
lRubber/plastics – dispose of in ordinary
waste.
lHoses – dispose of in ordinary waste.
lBatteries – keep separate and dispose of to
specialist contractor.
lAirbags (explosives) – keep separate and
dispose of to specialist contractor.
lElectrical components – send back to
supplier for refurbishment, or disassemble and
reuse any suitable parts. Dispose of the
remainder in ordinary waste.
lElectronic components – send back to
supplier for refurbishment, or disassemble and
reuse any suitable parts. Dispose of the
remainder in ordinary waste.
lCatalysts – can be sold if kept separate from
general waste.
lUsed spill-absorbing material – keep
separate and dispose of to specialist contractor.
lOffice waste – recycle paper and toner/ink
cartridges, dispose of the remainder in ordinary
waste.
Page 79 of 1007
GENERAL DATA
04-16
Fuel system - Td4 Diesel
System Common rail, direct injection
Fuel specification EN590 diesel*
⇒ Pump output 250 kPa (2.5 bar, 36.3 lbf.in
2)
Fuel pump
⇒ Up to 03 MY
⇒ Pump output
⇒ 03 MY onwardsElectric - submersible in fuel tank
250 kPa (2.5 bar, 36.3 lbf.in
2)
Fuel tank pump deleted, replaced by auxiliary delivery pump located
in RH rear wheel arch
Auxiliary delivery pump
⇒ Up to 03 MY
⇒ 03 MY onwardsElectrical - in line, located in engine compartment
Electrical - in line, located in RH rear wheel arch
Maximum delivery volume 240 litres per hour (52.75 imp. gallons) @ 12V
Fuel high pressure pump Bosch Cp1 mechanical high pressure, 3 radial piston
⇒ Drive Chain driven from crankshaft at 0.75 x engine speed
⇒ Pressure control Mounted on CP1, controlled by DDE 4.0
Pressure regulator
⇒ Up to 03 MY
⇒ 03 MY onwardsLocated in engine compartment between fuel filter and injection pump
Incorporated with in-tank suction and sender module
⇒ Pressure (nominal) 2.4 to 2.8 bar (34.8 to 40.6 lbf.in
2)
Injectors:
⇒ Make
⇒ Nozzle type
⇒ Position
⇒ Impedance
⇒ Injector operating pressureBosch CRI 0445 110 030
DSLA 145P 868
Central
14.5 Ω ± 5% @ 20%
250 - 1350 bar (3625 - 19575 lbf.in
2)
Injection begins:
⇒ Pre-injection (maximum) 60° BTDC
⇒ Main injection (maximum) 25° BTDC
⇒ Post injection 100 - 200° crank ATDC
Injection timing Controlled by Bosch DDE 4.0 engine management system for
common rail injection
Injection quantity 1 - 80 mm
3
Pre-delivery fuel pressure sensor
⇒ Up to 03 MY
⇒ 03 MY onwardsBosch / DS-K-400/50, located in filter head
Bosch /DS-K-400kPa, in-line, located in engine compartment
⇒ Pressure 400 kPa (58.0 lbf/in
2)
Fuel rail pressure sensor:
⇒ Measuring range 0 - 1500 bar (0-21750 lbf/in
⇒ Over pressure (max.) 1800 bar (26100 lbf/in
2)
⇒ Burst pressure 3000 bar (43500 lbf/in
2)
⇒ Temperature range -40°C to +120°C (-40°F to +248°F)
Fuel filter
⇒ Up to 03 MY
⇒ From 03 MYIn-line between auxiliary fuel pump and high-pressure fuel injection
pump, located in engine compartment
In-line, located in RH rear wheel arch
Page 81 of 1007
GENERAL DATA
04-18
Fuel system - K1.8 Petrol
Different octane ratings (98 RON) may be defined nationally; 90 — 98 RON if re-tuned via Testbook/T4 programme.
Leaded specifications will be available in certain markets. Alternative fuel specification (23% ethanol) is available in
certain markets.
Fuel system - KV6 Petrol
Different octane ratings (98 RON) may be defined nationally; 90 - 98 RON if re-tuned via Testbook/T4 programme.
Leaded specifications will be available in certain markets. Alternative fuel specification (23% ethanol) is available in
certain markets.
System Returnless multi-point fuel injection electronically controlled by
Motorola MEMS 3, ECM, with electro-mechanical fuel injectors
Fuel specification EN228, 95 unleaded*
Fuel rail Single nylon moulding with integral pressure damper
Injectors 4 x Bosch EV6E - MYJ 100550; air assisted, split stream targeted onto
back of inlet valves
Injector flow rate 117 g/min. @ 300 kPa (3.0 bar, 43.5 lbf.in
2)
Fuel pump Continuous flow, electrically driven roller vane pump submerged in
fuel tank
Fuel pressures 3.5 bar, 50.7 lbf.in
2)
Fuel pressure regulation Controlled by in-tank pressure regulator
Fuel pump delivery 39 litres @ 300 kPa (43.5 lbf.in
2)
Fuel filter In-tank, lifetime fit, Mesh area 584 cm
2; Mesh size 8 to 10 microns
Air cleaner Mann & Hummel paper element type
System:
⇒ Up to 03 MY
⇒ From 03 MYMulti-port, air assisted injection from pressure regulated, returnless supply
controlled by Siemens ECM and electro-mechanical injectors
Multi-port injection from pressure regulated, returnless supply controlled by
Siemens ECM and electro-mechanical injectors
Fuel specification EN228 95 RON unleaded*
Fuel rail:
⇒ Non NAS
⇒ NAS2 x nylon mouldings joined by steel crossover tube, pressure regulator on RH rail
Circular stainless steel returnless fuel rails with a nylon, multi-layer link pipe
Injectors:
⇒ Up to 03 MY
⇒ From 03 MY6 x air assisted, with twin sprays targeted on to back of inlet valves
6 with quadruple sprays targeted on to back of inlet valves
Injector flow rate 152 g/min. @ 350 kPa (3.5 bar, 50.7 lbf.in
2)
Injector air flow rate 1.0 kg/hour
Fuel pump Electric submersible
Fuel pressures 350 kPa (3.5 bar, 54.7 lbf.in
2)
Air filter Paper element type
Page 105 of 1007
TORQUE WRENCH SETTINGS
06-2
Engine – Td4
TORQUE DESCRIPTION METRIC IMPERIAL
Acoustic cover to engine 8 Nm 6 lbf.ft
Ancillary drive belt jockey pulley Allen bolt
*24 Nm 18 lbf.ft
Ancillary drive belt tensioner arm nut 10 Nm 7.5 lbf.ft
Big end bearing cap bolts:
⇒ Stage 15 Nm 3.5 lbf.ft
⇒ Stage 225 Nm 18 lbf.ft
⇒ Stage 3+70°+70°
Camshaft bearing cap bolts
† 10 Nm 7.5 lbf.ft
Camshaft cover bolts
† 10 Nm 7.5 lbf.ft
Camshaft sprocket retaining screw:
⇒ Stage 120 Nm 15 lbf.ft
⇒ Stage 2+35°+35°
Chain lubrication jet bolt 10 Nm 7.5 lbf.ft
Coolant rail to exhaust manifold bolts 20 Nm 15 lbf.ft
Coolant rail to exhaust manifold bolts 8 Nm 6 lbf.ft
Crankshaft pulley:
⇒ Stage 1100 Nm 74 lbf.ft
⇒ Stage 2+60 °+60 °
⇒ Stage 3+60 °+60 °
⇒ Stage 4+30 °+30 °
Crankshaft rear oil seal housing:
⇒ M6 bolts10 Nm 7.5 lbf.ft
⇒ M8 bolts22 Nm 16 lbf.ft
Cylinder block reinforcing plate 22 Nm 16 lbf.ft
Cylinder head bolts: (Stages 1 to 5 relate to bolts 1 to 11. Stage 6 is for bolt 12 only.)
⇒ Stage 1
†80 Nm 59 lbf.ft
⇒ Stage 2 - loosen all bolts
†-1/2 turn -1/2 turn
⇒ Stage 3
†50 Nm 37 lbf.ft
⇒ Stage 4
†+90°+90°
⇒ Stage 5
†+90°+90°
⇒ Stage 6 – tighten 41 mm bolt in position 12 110 Nm 81 lbf.ft
Cylinder head to timing cover Allen screws 15 Nm 11 lbf.ft
Dipstick tube to oil filter housing bolt 10 Nm 7.5 lbf.ft
Drive plate to crankshaft bolts
† 115 Nm 85 lbf.ft
EGR cooler to cylinder head and lifting bracket bolts 25 Nm 18 lbf.ft
Engine breather pipe to air cleaner housing bolt 10 Nm 7.5 lbf.ft
Engine lifting eye bolts 20 Nm 15 lbf.ft
Engine mounting bracket assembly to engine bolts 100 Nm 74 lbf.ft
Engine mounting bracket to hydramount nut 85 Nm 63 lbf.ft
Engine lower steady bracket bolts:
⇒ M1045 Nm 33 lbf.ft
⇒ M1250 Nm 37 lbf.ft
Engine steady mounting bolt 100 Nm 74 lbf.ft
Exhaust manifold to cylinder head nuts 24 Nm 18 lbf.ft
Flywheel to crankshaft bolts
† 115 Nm 85 lbf.ft
Fuel pipe bracket to oil filter housing bolt 10 Nm 7.5 lbf.ft
Fuel pipe union nuts 30 Nm 22 lbf.ft
Fuel pump drive chain lower guide Allen bolt 24 Nm 18 lbf.ft
Page 106 of 1007
TORQUE WRENCH SETTINGS
06-3
† Tighten in sequence
* Fit new bolt
Fuel pump sprocket retaining nut 65 Nm 48 lbf.ft
Fuel rail Allen screws 24 Nm 18 lbf.ft
Fuel rail to coolant rail bolts 10 Nm 7.5 lbf.ft
Fuel rail to support bracket bolts 10 Nm 7.5 lbf.ft
Glow plugs18 Nm 13 lbf.ft
Heatshield to coolant rail Allen screws 8 Nm 6 lbf.ft
Hose adaptor to cylinder head bolts 8 Nm 6 lbf.ft
LH engine mounting to gearbox bracket through bolt 100 Nm 74 lbf.ft
LH engine mounting to body 45 Nm 33 lbf.ft
Lower coolant rail support bracket bolts 15 Nm 11 lbf.ft
Main bearing cap bolts:
⇒ 1st. Stage
† 20 Nm 15 lbf.ft
⇒ 2nd Stage
† +70°+70°
Oil cooler to oil filter housing bolts 22 Nm 16 lbf.ft
Oil feed guide rail bolts 10 Nm 7.5 lbf.ft
Oil filter cap25 Nm 18 lbf.ft
Oil filter housing bolts 25 Nm 18 lbf.ft
Oil pick-up strainer to oil pump bolts 10 Nm 7.5 lbf.ft
Oil pressure switch 38 Nm 28 lbf.ft
Oil pump drive gear to oil pump drive shaft Torx bolt 25 Nm 18 lbf.ft
Oil pump to cylinder block 25 Nm 18 lbf.ft
PAS pipe clip to engine lifting eye bolt 10 Nm 7.5 lbf.ft
Sump: †
⇒ M6 bolts10 Nm 7.5 lbf.ft
⇒ M8 bolts28 Nm 21 lbf.ft
Sump drain plug28 Nm 21 lbf.ft
Sump plate bolts10 Nm 7.5 lbf.ft
Timing chain support guides 20 Nm 15 lbf.ft
Timing chain tensioner access plug 30 Nm 22 lbf.ft
Timing chain tensioner bolt 10 Nm 7.5 lbf.ft
Timing cover bolts
† 15 Nm 11 lbf.ft
Turbocharger to exhaust manifold bolts 45 Nm 33 lbf.ft
Turbocharger outlet pipe fixing bolts:
⇒ 6mm10 Nm 7.5 lbf.ft
⇒ 8mm25 Nm 18 lbf.ft
Vacuum pump bolts 22 Nm 16 lbf.ft