2001 LAND ROVER FREELANDER oil
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CONTENTS
CONTENTS 1
INTRODUCTION ...................................................................................... 01-1
How To Use This Manual................................................................................................................ 01-1
Repairs and Replacements ............................................................................................................. 01-2
Specifications .................................................................................................................................. 01-2
Abbreviations and Symbols ............................................................................................................ 01-3
GENERAL INFORMATION ...................................................................... 03-1
General precautions ........................................................................................................................ 03-1
Safety instructions ........................................................................................................................... 03-2
Environmental Precautions ............................................................................................................. 03-3
General fitting instructions .............................................................................................................. 03-7
Ball and roller bearings ................................................................................................................... 03-8
Oil seals .......................................................................................................................................... 03-9
Joints and joint faces ...................................................................................................................... 03-10
Locking devices .............................................................................................................................. 03-10
Screw threads ................................................................................................................................. 03-11
Bolt identification ............................................................................................................................. 03-12
Nut identification ............................................................................................................................. 03-13
Flexible pipes and hoses ................................................................................................................ 03-14
Service tools ................................................................................................................................... 03-16
Rolling road testing ......................................................................................................................... 03-17
Fuel handling precautions ............................................................................................................... 03-18
Electrical precautions ...................................................................................................................... 03-19
Supplementary restraint system precautions .................................................................................. 03-20
SRS component manual deployment ............................................................................................. 03-27
SRS component replacement policy ............................................................................................... 03-28
Air conditioning system precautions ............................................................................................... 03-29
Remedial actions ............................................................................................................................ 03-30
Service precautions ........................................................................................................................ 03-30
Air conditioning compressor replacement ....................................................................................... 03-31
Page 7 of 1007
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 8 of 1007
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
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 12 of 1007
CONTENTS
CONTENTS 9
AUTOMATIC GEARBOX - JATCO .......................................................... 44-1
ADJUSTMENTS
Inhibitor switch - adjust ................................................................................................................... 44-1
Gearbox fluid - drain & refill ........................................................................................................... 44-2
Selector cable - adjust .................................................................................................................. 44-3
REPAIRS
Selector housing ............................................................................................................................. 44-5
Gear knob ..................................................................................................................................... 44-6
Selector cable ................................................................................................................................. 44-7
Selector indicator - up to 03 MY ..................................................................................................... 44-8
Selector indicator - from 04MY ....................................................................................................... 44-9
Inhibitor switch ............................................................................................................................... 44-10
ECU ................................................................................................................................................ 44-10
Oil seal - torque converter............................................................................................................... 44-11
Gearbox - KV6 - with engine and gearbox removed ....................................................................... 44-12
Gearbox - KV6 ................................................................................................................................ 44-17
Gearbox - Td4 ................................................................................................................................. 44-23
Fluid pan - reseal ............................................................................................................................ 44-27
Fluid cooler - air blast - Td4 (hot climates) ...................................................................................... 44-28
Fluid cooler - Td4 ............................................................................................................................ 44-30
Fluid cooler - KV6 ........................................................................................................................... 44-31
Hose - fluid cooler .......................................................................................................................... 44-32
DRIVESHAFTS ......................................................................................... 47-1
REPAIRS
Shaft with both joints - LH ............................................................................................................... 47-1
Shaft with both joints - RH ............................................................................................................. 47-3
Gaiter - bell & joint - outer - front..................................................................................................... 47-5
Bell & joint - outer - LH - front ......................................................................................................... 47-5
Gaiter - inner joint ........................................................................................................................... 47-6
Shaft with both joints - rear ............................................................................................................. 47-6
Gaiter - outer - rear ......................................................................................................................... 47-8
Bell & joint - outer - rear .................................................................................................................. 47-8
Gaiter - inner joint - rear .................................................................................................................. 47-9
Propeller shaft assembly ................................................................................................................ 47-9
Propeller shaft - front ..................................................................................................................... 47-11
Propeller shaft - rear ....................................................................................................................... 47-12
Propeller shaft - front /rear - overhaul ............................................................................................. 47-13
Gaiter - sliding joint - front propeller shaft ....................................................................................... 47-14
Viscous coupling assembly ............................................................................................................ 47-15
Support bearing - front ................................................................................................................... 47-16
Page 13 of 1007
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
Page 23 of 1007
CONTENTS
20 CONTENTS
LIGHTING.................................................................................................. 86-2-1
ADJUSTMENTS
Headlamps - pair - align beam - up to 04MY .................................................................................. 86-2-1
Headlamps - pair - align beam - from 04MY ................................................................................... 86-2-1
REPAIRS
Headlamp assembly - up to 04MY.................................................................................................. 86-2-3
Headlamp assembly - from 04MY .................................................................................................. 86-2-4
Lamp assembly - flasher side repeater - front ................................................................................ 86-2-5
Lamp assembly - tail ....................................................................................................................... 86-2-5
Lamp assembly - number plate ...................................................................................................... 86-2-6
Lamp assembly - fog/driving - from 04MY ...................................................................................... 86-2-6
Lamp assembly - rear ..................................................................................................................... 86-2-7
Lamp assembly - centre high mounted stop (CHMSL) ................................................................... 86-2-7
Lamp assembly - glove compartment ............................................................................................. 86-2-8
Lamp assembly - load space .......................................................................................................... 86-2-8
Switch - headlamp levelling ............................................................................................................ 86-2-9
Switch - glove compartment ........................................................................................................... 86-2-9
Switch - hazard warning ................................................................................................................. 86-2-10
Switch - combined direction indicator/headlight/horn ..................................................................... 86-2-10
Switch - rear fog lamp ..................................................................................................................... 86-2-11
CONTROL UNITS ..................................................................................... 86-3-1
REPAIRS
Control unit - window lift ................................................................................................................. 86-3-1
Relay - power folding mirrors - from 02MY ..................................................................................... 86-3-1
Central Control Unit (CCU) ............................................................................................................. 86-3-2
Control Unit - power fold mirrors - up to 02MY ............................................................................... 86-3-3
SECURITY................................................................................................. 86-4-1
REPAIRS
Solenoid/motor - taildoor................................................................................................................. 86-4-1
Switch/push - horn .......................................................................................................................... 86-4-2
Horn ................................................................................................................................................ 86-4-2
Immobilisation - electronic control unit (ECU) - ............................................................................. 86-4-3
Sensor - volumetric - alarm system - 3 door ................................................................................... 86-4-3
Module (ECU) - volumetric - alarm system - 5 door - without sunroof ........................................... 86-4-5
Module (ECU) - volumetric - alarm system - 5 door - with sunroof ................................................ 86-4-7
Receiver - alarm system ................................................................................................................. 86-4-10
Coil - passive immobilisation - alarm system .................................................................................. 86-4-10
Page 32 of 1007
GENERAL INFORMATION
03-1
GENERAL INFORMATION
General precautions
Dangerous substances
Modern vehicles contain many materials and liquids
which if not handled with care can be hazardous to
both personal health and the environment.
WARNING: Many liquids and other substances
used in motor vehicles are poisonous and should
under no circumstances be consumed and
should, as far as possible, be kept from contact
with the skin. These liquids and substances
include acid, anti-freeze, asbestos, brake fluid,
fuel, windscreen washer additives, lubricants,
refrigerants and various adhesives.
Always read carefully the instructions printed on
labels or stamped on components and obey them
implicitly. Such instructions are included for
reasons of your health and personal safety.
Never disregard them.
WARNING: Many of the fluids used in motor
vehicles, such as coolant, brake fluid and power
steering fluid, are inflammable. Take care not to
spill fluids when topping-up, a fire may result. If
spillage does occur, ensure the area is
thoroughly cleaned before starting the engine.
Synthetic rubber
Many 'O' rings, seals, hoses, flexible pipes and other
similar items which appear to be natural rubber, are
in fact, made of synthetic materials called
Fluoroelastomers.
Under normal operating conditions this material is
safe and does not present a health hazard. However,
if the material is damaged by fire or excessive
heating, it can break down and produce highly
corrosive Hydrofluoric acid which can cause serious
burns on contact with skin.
If skin contact does occur:
lRemove any contaminated clothing
immediately.
lIrrigate effected area of skin with a copious
amount of cold water or limewater for 15 to 60
minutes.
lObtain medical assistance immediately.
Should any material be in a burnt or over-heated
condition, handle with extreme caution and wear
protective clothing (seamless industrial gloves,
protective apron etc.). Decontaminate and dispose of
gloves immediately after use.Lubricating oils
WARNING: Avoid excessive skin contact with used
engine oil. Used engine oil contains potentially
harmful contaminants which may cause skin cancer
or other serious skin disorders.
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats from
the skin, leading to dryness, irritation and dermatitis.
Health protection precautions
The following precautions should be observed at all
times:
lAvoid prolonged and repeated contact with oils,
particularly used engine oils.
lWear protective clothing, including impervious
gloves where practicable.
lDo not put oily rags in pockets.
lAvoid contaminating clothes (particularly those
next to the skin) with oil.
lOveralls must be cleaned regularly. Discard
heavily soiled clothing and oil impregnated
footwear.
lFirst aid treatment should be obtained
immediately for open cuts and wounds.
lUse barrier creams: apply before each work
period to help prevent lubricating oil from
contaminating the skin.
lWash with soap and water to ensure all oil is
removed (propriety skin cleansers and nail
brushes will help).
lUse moisturisers after cleaning; preparations
containing lanolin help replace the skin's natural
oils which have been removed.
lDo not use petrol, kerosene, diesel fuel, gas, oil,
thinners or solvents for cleaning skin.
lIf skin disorders develop, obtain medical advice
without delay.
lWhere practicable, degrease components prior
to handling.
lWear eye protection (e.g. goggles or face
shield) if there is a risk of eye contamination.
Eye wash facilities should be provided in the
close vicinity of the work area.