gearbox LAND ROVER FREELANDER 2001 Owner's Manual

TORQUE WRENCH SETTINGS
06-6
Engine – KV6
TORQUE DESCRIPTION METRIC IMPERIAL
Bearing ladder to cylinder block bolts
†
⇒ Stage 120 Nm 15 lbf.ft
⇒ Stage 2+90 °+90 °
Camshaft carrier to cylinder head bolts
†++10 Nm 7.5 lbf.ft
Camshaft cover to carrier bolts
†9 Nm 7 lbf.ft
Camshaft timing belt cover bolts 4 Nm 3 lbf.ft
Camshaft timing belt front cover backplate to cylinder head bolts
+9 Nm 7 lbf.ft
Camshaft timing belt rear cover backplate to cylinder head bolts
+9 Nm 7 lbf.ft
Camshaft timing belt tensioner bolts 25 Nm 18 lbf.ft
Camshaft timing gear bolts *
⇒ Stage 127 Nm 20 lbf.ft
⇒ Stage 2+90 °+90 °
Camshaft position sensor bracket to camshaft cover bolt 9 Nm 7 lbf.ft
Connecting rod big-end bolts
⇒ Stage 120 Nm 15 lbf.ft
⇒ Stage 2+45 °+45 °
Crankcase (lower) to cylinder block bolts
⇒ M6 bolts
+++25 Nm 7 lbf.ft
⇒ M8 bolts
+++25 Nm 18 lbf.ft
Crankshaft pulley bolt 160 Nm 118 lbf.ft
Crankshaft rear oil seal to cylinder block bolts
* † 8 Nm 6 lbf.ft
Cylinder head bolts
†
⇒ Stage 125 Nm 18 lbf.ft
⇒ Stage 218 lbf.ft 18 lbf.ft
⇒ Stage 325 Nm 18 lbf.ft
⇒ Stage 4+180 °+180 °
Drain plug to sump 25 Nm 18 lbf.ft
Drive plate to crankshaft bolts
†
⇒ Stage 1
⇒ Stage 225 Nm
100 Nm18 lbf.ft
74 lbf.ft
Earth lead to RH camshaft cover bolt 9 Nm 7 lbf.ft
Engine front mounting plate to cylinder block and IRD bracket
⇒ M10 bolt - No. 1 on tightening sequence 25 Nm 18 lbf.ft
⇒ M10 bolt - No. 5 on tightening sequence 45 Nm 33 lbf.ft
⇒ M12 bolts85 Nm 63 lbf.ft
Engine mounting bracket to engine front plate bolts 45 Nm 33 lbf.ft
Engine mounting (LH) to body bolts 45 Nm 33 lbf.ft
Engine mounting bracket (LH) to gearbox bracket through bolt 85 Nm 63 lbf.ft
Engine mounting bracket (LH) to gearbox bracket through bolt 100 Nm 74 lbf.ft
Engine steady (lower) to sump bracket and subframe bolts 100 Nm 74 lbf.ft
Engine steady (upper RH) to body bolts 100 Nm 74 lbf.ft
Engine steady (upper RH) to top arm bolt 100 Nm 74 lbf.ft
Fuel rail to inlet manifold bolts 9 Nm 7 lbf.ft
Heat shield (RH rear timing belt) to cylinder head bolts
⇒ M69 Nm 7 lbf.ft
⇒ M825 Nm 18 lbf.ft
Hydramount (RH)85 Nm 63 lbf.ft
Idler pulley to engine front mounting plate Allen bolt 45 Nm 33 lbf.ft

TORQUE WRENCH SETTINGS
06-7
† Tighten in sequence
*New bolts must be fitted
+ Apply sealant, Part No. STC50552 to threads
++ Apply sealant, Part No. STC 4600 to threads
+++ Apply sealant, Part No. STC 50550 to threads
Ignition coils to LH inlet manifold nut and bolts 9 Nm 7 lbf.ft
Ignition plug top coils to spark plug bolts 9 Nm 7 lbf.ft
Inlet manifold to cylinder head nuts and bolts 25 Nm 18 lbf.ft
IRD support bracket to front mounting plate bolts 45 Nm 33 lbf.ft
IRD support bracket to sump bolts 45 Nm 33 lbf.ft
LH mounting to body bolts 48 Nm 35 lbf.ft
LH mounting bracket to gearbox bolts 85 Nm 63 lbf.ft
LH mounting to gearbox bracket through bolt 100 Nm 74 lbf.ft
Oil cooler to sump mounting bracket nuts 25 Nm 18 lbf.ft
Oil cooler pipes to oil filter and oil cooler unions 26 Nm 19 lbf.ft
Oil dipstick tube bracket to cylinder block bolt 9 Nm 7 lbf.ft
Oil pick-up strainer to bearing ladder bolts
+8 Nm 6 lbf.ft
Oil pressure relief valve plug nut
+25 Nm 18 lbf.ft
Oil pressure switch 14 Nm 10 lbf.ft
Oil pump to cylinder block bolts
†
⇒ Stage 1
⇒ Stage 25 Nm
9 Nm4 lbf.ft
7 lbf.ft
PAS pipe to engine front mounting plate bolt 25 Nm 18 lbf.ft
PAS pipe support bracket to RH hydramount nut 85 Nm 63 lbf.ft
Sump to lower crankcase bolts
†++35 Nm 26 lbf.ft
Timing belt cover (front LH and RH) bolts 4 Nm 3 lbf.ft
Timing belt cover (lower) to cylinder block bolts 9 Nm 7 lbf.ft
Timing belt cover (rear LH and RH) bolts 4 Nm 3 lbf.ft
Rear timing belt cover backplate bolts 9 Nm 7.5 lbf.ft
Top arm to RH hydramount nut 85 Nm 63 lbf.ft
Top arm bracket to engine front plate and RH mounting bolts 100 Nm 74 lbf.ft

TORQUE WRENCH SETTINGS
06-18
Clutch
† Tighten in diagonal sequence
TORQUE DESCRIPTION METRIC IMPERIAL
Clutch assembly to flywheel Allen screws
† 25 Nm 18 lbf.ft
Clutch slave cylinder mounting bracket to gearbox bolts 25 Nm 18 lbf.ft
Inertia switch bolt8 Nm 6 lbf.ft
Pressure plate to flywheel Torx bolts
†25 Nm 18 lbf.ft

TORQUE WRENCH SETTINGS
06-19
Manual Gearbox – PG1
+ Apply sealant, Part No. STC 50552 to threads of 2 top bolts
TORQUE DESCRIPTION METRIC IMPERIAL
Clutch slave cylinder mounting bracket to gearbox bolts 25 Nm 18 lbf.ft
Drain plug35 Nm 26 lbf.ft
Filler / level plug35 Nm 26 lbf.ft
1st. gear switch24 Nm 18 lbf.ft
Front cover plate to gearbox bolt and nut 9 Nm 7 lbf.ft
Gearbox to engine bolts
+80 Nm 59 lbf.ft
Gearbox to sump bolts 45 Nm 33 lbf.ft
Gear change steady rod to mounting bracket bolt 25 Nm 18 lbf.ft
Lifting bracket to gearbox bolt 45 Nm 33 lbf.ft
LH engine mounting to gearbox bolts 65 Nm 48 lbf.ft
LH engine mounting to gearbox bolts 80 Nm 59 lbf.ft
Reverse light switch 24 Nm 18 lbf.ft

TORQUE WRENCH SETTINGS
06-20
Manual Gearbox – Getrag
+ Apply sealant, Part No. STC 4600 to threads
TORQUE DESCRIPTION METRIC IMPERIAL
Earth lead to gearbox bolt 25 Nm 18 lbf.ft
Engine LH mounting to body bolts (KV6) 48 Nm 35 lbf.ft
1st gear switch to gearbox 24 Nm 18 lbf.ft
Gearbox drain plug 35 Nm 26 lbf.ft
Gearbox casing end cover Torx bolts 25 Nm 18 lbf.ft
Gearbox filler / level plug 35 Nm 26 lbf.ft
Gearbox closing plate bolts 10 Nm 7 lbf.ft
Gearbox to engine bolts 85 Nm 63 lbf.ft
Gearbox to LH engine mounting bolts (KV6) 85 Nm 63 lbf.ft
Gear change cover bolts 25 Nm 18 lbf.ft
Gearbox mounting bracket to gearbox bolts 85 Nm 63 lbf.ft
Gearbox mounting bracket to gearbox bolts 100 Nm 74 lbf.ft
Gearbox mounting bracket to LH engine mounting through bolt 100 Nm 74 lbf.ft
Gearbox to engine bolts 85 Nm 63 lbf.ft
Gearbox rear cover Torx bolts
+25 Nm 18 lbf.ft
Gear change cover to selector shaft Torx bolts
+25 Nm 18 lbf.ft
LH engine mounting to gearbox bracket bolts 100 Nm 74 lbf.ft
Release bearing sleeve bolts 12 Nm 9 lbf.ft
Reverse lamp switch to gearbox 24 Nm 18 lbf.ft

TORQUE WRENCH SETTINGS
06-21
Intermediate Reduction Drive
+ Apply sealant, Part No. STC 4600 to threads
TORQUE DESCRIPTION METRIC IMPERIAL
Drain plug35 Nm 26 lbf.ft
Exhaust heatshield to exhaust mounting bracket 45 Nm 33 lbf.ft
Exhaust heatshield to IRD screws (Td4) 30 Nm 22 lbf.ft
Exhaust heatshield to IRD nut (K1.8 and KV6) 45 Nm 33 lbf.ft
Filler / level plug35 Nm 26 lbf.ft
IRD unit to gearbox bolts 90 Nm 66 lbf.ft
IRD end cover bolts
+30 Nm 22 lbf.ft
IRD support bracket to cylinder block bolt (K1.8) 48 Nm 35 lbf.ft
IRD support bracket to cylinder block bolt (K1.8) 48 Nm 35 lbf.ft
IRD support bracket to IRD bolts (Td4)
⇒ M8
⇒ M1030 Nm
50 Nm22 lbf.ft
37 lbf.ft
IRD support bracket to IRD bolts (K1.8 and KV6) 50 Nm 37 lbf.ft
IRD support bracket to sump (K1.8 and KV6) 88 Nm 65 lbf.ft
Lower engine steady to IRD support bracket bolts 100 Nm 74 lbf.ft
Manifold heatshield to IRD support bracket bolts (K1.8 and KV6) 9 Nm 6.5 lbf.ft
Manifold heatshield to IRD support bracket bolts (K1.8 and KV6) 25 Nm 18 lbf.ft
Manifold heatshield to pinion housing nut (KV6) 45 Nm 33 lbf.ft
Manifold heatshield to IRD (Td4) 30 Nm 22 lbf.ft
Breather pipe bracket screw 9 Nm 7 lbf.ft
Mass damper to pinion housing nuts (K1.8) 25 Nm 18 lbf.ft
Pinion nut150 Nm 111 lbf.ft
Pinion housing nuts 25 Nm 18 lbf.ft
Propeller shaft to IRD flange bolts 40 Nm 30 lbf.ft

TORQUE WRENCH SETTINGS
06-22
Automatic Gearbox – Jatco
†Tighten in sequence.
+ Apply sealant, Part No. STC 4600 to threads
TORQUE DESCRIPTION METRIC IMPERIAL
Air blast cooler assembly to chassis bolts:
⇒ Lower10 Nm 7.5 lbf.ft
⇒ Upper5 Nm 3.5 lbf.ft
Air blast cooler fan cowl to matrix bolts 5 Nm 3.5 lbf.ft
Air blast cooler fan motor to cowl bolts 5 Nm 3.5 lbf.ft
Air blast cooler multiplug mounting bracket nut 10 Nm 7.5 lbf.ft
Air blast cooler pipe union nuts 25 Nm 18 lbf.ft
Crankshaft Position (CKP) Sensor 9 Nm 7 lbf.ft
Closing panel to gearbox panel bolt 10 Nm 7.5 lbf.ft
Drive plate to converter bolts 45 Nm 33 lbf.ft
Earth lead to gearbox housing bolt 25 Nm 18 lbf.ft
Fluid cooler to mounting bracket bolts (KV6) 25 Nm 18 lbf.ft
Fluid cooler mounting bracket bolts (KV6):
⇒ M825 Nm 18 lbf.ft
⇒ M1285 Nm 63 lbf.ft
Fluid cooler mounting bolts (Td4):
⇒ 2 off45 Nm 33 lbf.ft
⇒ 1 off25 Nm 18 lbf.ft
Fluid cooler hoses to gearbox 18 Nm 13 lbf.ft
Fluid cooler hose unions 18 Nm 13 lbf.ft
Fluid pan bolts
† +7 Nm 5 lbf.ft
Gearbox closing plate bolt (Td4) 10 Nm 7.5 lbf.ft
Gearbox drain plug 45 Nm 33 lbf.ft
Gearbox level plug 14 Nm 10 lbf.ft
Gearbox housing to sump 85 Nm 63 lbf.ft
Gearbox to engine bolts 85 Nm 63 lbf.ft
Gearbox mounting bracket bolts 85 Nm 63 lbf.ft
Gearbox mounting through bolt 100 Nm 74 lbf.ft
Inhibitor switch bolts 3 Nm 2.2 lbf.ft
IRD cooling hose retainer bolt (KV6) 25 Nm 18 lbf.ft
IRD support bracket mounting bolts
† (KV6) 50 Nm 37 lbf.ft
IRD support bracket to engine front mounting bracket bolts
† (KV6) 50 Nm 37 lbf.ft
IRD support bracket to sump bolts
† (KV6) 45 Nm 33 lbf.ft
IRD to gearbox bolts (KV6) 80 Nm 59 lbf.ft
Manifold heatshield to IRD support bracket (KV6):
⇒ Bolts9 Nm 7 lbf.ft
⇒ Nut45 Nm 33 lbf.ft
Manifold heatshield to IRD pinion housing nut (KV6) 25 Nm 18 lbf.ft
Selector housing nuts 10 Nm 7.5 lbf.ft
Selector cable trunnion nut 6 Nm 4.5 lbf.ft
Selector lever to gearbox selector shaft nut 25 Nm 18 lbf.ft
Starter motor to gearbox bolts 45 Nm 33 lbf.ft
Torque converter access plate bolts 9 Nm 7 lbf.ft

LIFTING AND TOWING
08-1
LIFTING AND TOWING
Jacking
The following instructions must be carried out before
raising the vehicle off the ground:
lUse a solid level surface.
lApply parking brake.
lSelect 1st. gear in main gearbox and ensure
HDC is not selected.
CAUTION: To avoid damage to under body
components of the vehicle, adhere to the
following jacking procedures:
DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS:
lBumpers
lBrake or Fuel lines
lExhaust pipe
lSuspension components
lSteering rack and linkages
lFuel tank
lEngine sump
lGearbox
lIRD unit
Jack or support vehicle only on approved jacking
points as detailed in the following illustration:
Front (hydraulic jack) and side (vehicle jack) jacking
pointsSafety stand positions under longitudinal members
Rear (hydraulic jack) and side (vehicle jack) jacking
points
Vehicle jack
The jack provided with the vehicle is only intended to
be used in an emergency, for changing a tyre. Do
NOT use the jack for any other purpose. Refer to the
Owner's Handbook for vehicle jack location points
and procedure. Never work under a vehicle only
supported by the vehicle jack.
Hydraulic jack
A hydraulic jack with a minimum 1500 kg (3,300 lbs)
load capacity must be used.
WARNING: Do not work on or under a vehicle
supported only by a jack. Always support the
vehicle on safety stands.

LIFTING AND TOWING
08-2
Raising the front of a vehicle
Position the cup of the hydraulic arm under the
centre of the front body crossmember assembly.
Use jack to raise front road wheels to enable safety
stands to be installed under the front end of each
longitudinal member.
Carefully lower jack until vehicle sits securely on
safety stands.
Before working on the underside of a vehicle re-
check the stability of the vehicle on the stands.
Use the reverse procedure when removing a vehicle
from stands.
NOTE: For some repair operations it may be
necessary to use a jack to support the engine under
the sump. In this case, a block of wood should be
used on the jack to protect the sump.
Raising the rear of a vehicle
Position cup of hydraulic arm under the centre of the
rear subframe crossmember at the position
identified by the embossed arrows.
Use jack to raise rear road wheels to enable safety
stands to be installed under the rear ends of the
body longitudinal members.
Carefully lower jack until vehicle sits securely on
safety stands.
Before working on the underside of a vehicle, re-
check the stability of the vehicle on the stands.
Use the reverse procedure when removing a vehicle
from stands.
Wheel-free lift
Locate the lifting pads under the ends of the body
longitudinal members. Raise the ramp to support the
weight of the vehicle, ensure the vehicle is secure on
the lifting pads, then raise the ramp to the required
height.
Towing
General
The vehicle has permanent four wheel drive. The
following instructions must be adhered to:
Towing the vehicle on all four wheels with driver
operating steering and brakes
lTurn ignition key to position '1' to release
steering lock and then to position 'II' to enable
the brake lights, wipers and direction indicators
to be operated, if necessary.
l Select neutral in gearbox and ensure HDC (hill
descent control) is deselected.
lSecure tow rope, chain or cable to towing eye.
lRelease the parking brake.
CAUTION: The brake servo and power assisted
steering system will not be functional without the
engine running. Greater pedal pressure will be
required to apply the brakes and the steering
system will require greater effort to turn the front
road wheels. The vehicle tow connection should
only be used under normal road conditions,
'snatch' recovery should be avoided.
Suspended tow by breakdown vehicle
Mark propeller shaft drive flanges and mating flanges
with identification lines to enable the propeller shaft
to be refitted in its original position.
Remove the propeller shaft fixings then remove the
shaft from the vehicle.
CAUTION: To prevent vehicle damage, rear
propeller shaft MUST BE removed.

LIFTING AND TOWING
08-4
Emergency starting
WARNING: Battery fluid (electrolyte) contains
sulphuric acid. It may cause severe burns if it
gets on your skin or in your eyes. Wear
protective clothing and a face shield.
If electrolyte gets on your skin or clothes,
immediately rinse it off with water.
If electrolyte gets in your eyes, immediately flush
eyes with water for at least 15 minutes and seek
medical help.
To Jump Start - Negative Ground Battery
Position vehicles so that jump leads will reach,
ensuring that vehicles DO NOT TOUCH,
alternatively a fully charged slave battery may be
positioned on the floor adjacent to the vehicle.
Ensure that:
lthe ignition and all electrical accessories are
switched off
lthe parking brake is applied and neutral is
selected on gearbox
Connect the jump leads as follows:
WARNING: Making final cable connection could
cause an electrical arc, which if made near
battery could cause an explosion.
aConnect one end of first jumper cable to
positive (+) terminal of booster battery.
bConnect other end of first jumper cable to
positive (+) terminal of discharged battery.
cConnect one end of second jumper cable to
negative terminal of booster battery.
dConnect other end of second jumper cable to a
good earth point on the engine, NOT TO
NEGATIVE TERMINAL OF DISCHARGED
BATTERY.
CAUTION: Keep jumper leads away from moving
parts, pulleys, drive belts and fan blade
assembly.If the booster battery is installed in another vehicle,
start engine and allow to idle.
Start engine of vehicle with discharged battery,
following starting procedure in Owners' Handbook.
CAUTION: If vehicle fails to start within a
maximum time of 12 seconds, switch ignition off
and investigate cause. Failure to follow this
instruction could result in irreparable damage to
catalyst.
To disconnect:
l Remove negative (-) jumper cable from the
engine and then terminal of booster battery.
lRemove positive (+) jumper cable from positive
terminals of booster battery and discharged
battery.