fuel cap LAND ROVER FREELANDER 2001 User Guide

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
09-1
CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
Capacities
The following capacities are only an approximation of
the amount of fluid required to fill the respective
system.
Capacities – UK/ROW
† An extra 420 cc (0.73 imp pt) is required for
vehicles with an air blast fluid cooler fitted.
* Refill capacity is approx. 0.7 litre (1.125 imp. pt)
less than the from dry figures.
Capacities – NAS
Component / system Capacity
Fuel tank:
Td4 Model
K1.8 and KV6 Models
⇒ Up to 03 Model Year
⇒ From 03 Model Year
KV6 Model
⇒ Up to 03 Model Year
⇒ From 03 Model Year59 litres (13 gallons)
59 litres (13 gallons)
64 litres (14.3 gallons)
59 litres (13 gallons)
64 litres (14.3 gallons)
Engine - Td4 (including oil cooler and oil filter):
⇒ Refill 6.8 litres (12 imp. pts)
⇒ Fill from dry 7.3 litres (12.9 imp. pts)
Engine - K1.8 (including filter):
⇒ Refill 4.5 litres (7.9 imp. pts)
⇒ Fill from dry 4.8 litres (8.4 imp. pts)
Engine - KV6 (including oil cooler and filter):
⇒ Refill 5.2 litres (9.125 imp. pts)
⇒ Fill from dry 6.0 litres (10.625 imp. pts)
Manual gearbox - PG1:
⇒ Refill 2.0 litres (3.5 imp. pts)
⇒ From dry 2.2 litres (3.9 imp. pts)
Manual gearbox - Getrag:
⇒ Refill 1.6 litres (2.875 imp. pts)
⇒ From dry 1.67 litres (3 imp. pts)
Automatic gearbox - JATCO:
⇒ Refill 4.0 litres (7 imp. pts)
⇒ From dry
†8.5 litres (15 imp. pts)
Intermediate Reduction
Drive1.1 litres (2 imp. pts)
Rear differential:
⇒ Maximum 830 ml (29.2 imp. fl. oz.)
⇒ Minimum 750 ml (26.4 imp. fl. oz.)
Power steering reservoir 335 cm
3
Cooling system - Td4 Engine – Fill from dry (with
reservoir)*:
⇒ Automatic - Up to 03
Model Year
⇒ Automatic - From 03
Model Year7.25 litres (12.8 imp. pts)
7.35 litres (13 imp. pts)
⇒ Manual 7.25 litres (12.8 imp. pts)
Cooling system - K1.8 Engine:
⇒ Fill from dry (with
reservoir)*5.8 litres (10.25 imp. pts)
Cooling system - KV6 Engine:
⇒ Fill from dry (with
reservoir)*7.8 litres (13.75 imp. pts)
Reservoir tank:
⇒ Maximum fill 0.44 litres (0.75 imp. pts)
⇒ Expansion tank volume 1.2 litres (2.125 imp. pts)
⇒ Gross expansion
capacity0.72 litres (1.27 imp. pts)
Windscreen washer
reservoir 4.0 litres (7 imp. pints)
Component / system Capacity
Fuel tank:
⇒ Up to 02.5 Model Year
⇒ From 02.5 Model Year15.6 US gallons
17.2 US gallons
Engine - KV6 (including oil cooler and filter):
⇒ Engine oil and filter
change11 US pts
⇒ Fill from dry 12.7 US pts
Automatic gearbox - JATCO:
⇒ Refill 8.5 US pts
⇒ From dry 18.2 US pts
Intermediate Reduction
Drive2.3 US pts
Rear differential:
⇒ Maximum
⇒ Minimum28.1 US fl. oz.
25.4 US fl. oz.
Power steering reservoir 335 cm
3
Cooling system - KV6 Engine:
⇒ Fill from dry (with
reservoir)17.82 US pts
Reservoir tank:
⇒ Maximum fill 0.93 US pts
⇒ Expansion tank volume 2.54 US pts
⇒ Gross expansion
capacity1.52 US pts
Windscreen washer
reservoir 8.5 US pts Component / system Capacity

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
09-2
Fluids
Fuel
Always use the following recommended fuels:
Petrol engines
Use unleaded petrol with a minimum octane rating of
95 RON to ENN 228 specification.
In an emergency (and only if the correct fuel is
unavailable), lower octane rated fuel can be used for
very limited periods of moderate, low speed
motoring, provided engine 'knocking' does not occur.
Fuels of 90 RON is used in certain markets; 90 RON
fuel can be used regularly ONLY if the engine has
been tuned specifically to suit low octane fuel.
Certain markets use fuel containing a 23% Ethanol
additive.
K1.8 and KV6 engines are also available for use with
a low octane leaded fuel specification in some
markets.
Diesel engines
Use a good quality diesel fuel or automotive gas oil
(AGO) conforming to EN 590 specification.
It is important that the sulphur content of diesel fuel
does not exceed 0.3%.
Ensure the fuel filter element is changed at the
recommended intervals.

+ MAINTENANCE, MAINTENANCE, Fuel
Filter - Diesel.
Brake Fluid
Use only DOT 4 brake fluid. DO NOT use brake fluid
of a different specification.
PAS fluid
Use Texaco 9226 fluid.Anti-freeze solutions
The overall anti-freeze concentration should not fall,
by volume, below 50% to ensure that the anti-
corrosion properties of the coolant are maintained.
Anti-freeze concentrations greater than 60% are not
recommended as cooling efficiency will be impaired.
Use Havoline Extended Life Coolant (XLC), or any
ethylene glycol based anti-freeze (containing no
methanol) with only Organic Acid Technology (OAT)
corrosion inhibitors, to protect the cooling system.
CAUTION: No other anti-freeze should be used
with Havoline Extended Life Coolant.
The cooling system should be drained, flushed and
refilled with the correct amount of anti-freeze
solution at the intervals given on the Service
Maintenance Check Sheet.
After filling with anti-freeze solution, attach a warning
label to a prominent position on the vehicle stating
the type of anti-freeze contained in the cooling
system to ensure that the correct type is used for
topping-up.
The following recommended quantities of anti-freeze
will provide frost protection to -36 °C (-33 °F):
Engine – Td4
Engine – K1.8
Engine – KV6
Concentration 50%
Amount of anti-freeze 3.75 litres
(6.625 imp. pts)
Concentration 50%
Amount of anti-freeze 2.9 litres
(5.125 imp. pts)
Concentration 50%
Amount of anti-freeze 3.9 litres
(6.875 imp. pts, )

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
09-3
Lubrication
The engine and other lubricating systems are filled
with high- performance lubricants giving prolonged
life.
CAUTION: Always use a high quality oil of the
correct viscosity range in the engine. The use of
oil of the incorrect specification can lead to high
oil and fuel consumption and ultimately to
damaged components.
Oil to the correct specification contains additives
which disperse the corrosive acids formed by
combustion and prevent the formation of sludge
which can block the oil ways. Additional oil additives
should not be used.
Always adhere to the recommended servicing
intervals.
Engine oil
Engine oil viscosity / temperature ranges are
indicated in the following table:
a0W/30; 5W/30
b0W/40, 50, 60; 5W/40, 50, 60
c10W/30
d10W/40, 50, 60
Engine oil – Td4 engine
Use 0W/30 or 5W/40, 50, 10W/30, 40, 60 oil meeting
ACEA A3/B3 specifications, and having a viscosity
band recommended for the temperature range of
your locality. Where oils to these European
specifications are not available, well known brands of
oils meeting API SH quality should be used.Engine oil – K1.8 engine
Use a 10W/40 oil meeting specification ACEA A2 or
A3.
Engine oil – KV6 engine – Non NAS models
Use a 10W/40 oil meeting specification ACEA A2 or
A3.
Engine oil – KV6 engine - NAS models
Use a 5W/40 fully synthetic oil meeting specification
ACEA A3. Where oils to these European
specifications are not available, well known brands of
oils meeting API SH quality should be used.
Gearbox oil
Use of gearbox oils other than those specified may
result in serious damage to the gearbox.
Manual Gearbox – PG1 and Getrag
Use OPEL B 0400063 for refill or topping-up.
Automatic Gearbox – JATCO
Use Texaco N402 fluid for refill or topping-up.
Intermediate Reduction Drive
Texaco S5 75W90; Synthetic oil or equivalent,
meeting: API GL5
Rear Differential
Multigear 80W/90 ETL; Specification: API GL5
Gear linkage - Manual
Use grease containing 3% Molybdenum Disulphide.
General Greasing
Use Multipurpose Lithium Base Grease NLGI
consistency No. 2.
Bonnet latch
Lubricate cable and latch with oil.

MAINTENANCE
MAINTENANCE 10-11
Door Locks, Hinges, Check Straps and
Bonnet Catch
Check
1.Check operation of each door, door lock,
bonnet catch and fuel filler flap.Lubricate Front and Rear Doors
1.Open each door in turn and lubricate door
hinges and check strap using recommended
lubricant.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
2.Lubricate door lock, striker and private lock
using PTFE lubricant. Remove excessive
lubricant, particularly from door striker area, to
avoid customer complaint.
3.Check tightness of accessible door lock and
striker fixings.
4.Open and close door to check for smooth,
noise-free operation. Ensure door closes
securely.
5.Check for smooth operation of private lock.
Lubricate Tail Door
1.Open tail door and lubricate hinges using
recommended lubricant.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
2.Grease tail door check slide.
3.Lubricate rear door lock and striker using PTFE
lubricant. Remove excessive lubricant to avoid
customer complaint, particularly from door
striker area.
4.Check tightness of accessible tail door lock and
striker fixings.
Lubricate Bonnet
1.With bonnet open, lubricate hinges, striker, lock
and safety catch using a suitable lubricant.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
Sunroof Guide Rails, Slides and Seal
1.With sunroof open, lubricate accessible guide
rails, slides and seals. Remove any excess
lubricant to avoid contaminating roof lining and
trim.
2.Ensure sunroof closes correctly.
Sunroof Drain Tubes and Channels
1.Remove any debris from sunroof tray.
2.Ensure that all accessible sunroof drain tubes
are clear using a low pressure air line.

FUEL DELIVERY SYSTEM - PETROL
ADJUSTMENTS 19-2-3
Fuel system - depressurise - KV6 - NAS
$% 19.50.02
Check
1.Remove acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
2. Up to 03MY: Remove nut and bolt securing coil
and position coil aside.
3.Remove schraeder valve cap.
4.Position absorbent cloth around fuel feed pipe
connection to collect spillage.
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.5.Connect adapter LRT-19-006 to schraeder
valve.
6.Position opposite end of adapter LRT-19-006
into container, turn tap to release pressure.
7.Remove adapter LRT-19-006 from schraeder
valve.
8.Fit cap to schraeder valve.
9. Up to 03MY: Fit and tighten nut and bolt
securing coil.
10.Fit acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.

FUEL DELIVERY SYSTEM - PETROL
ADJUSTMENTS 19-2-5
Fuel system - pressure test - KV6 - NAS
$% 19.50.13
Remove
1.Remove acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
2.Position absorbent cloth beneath fuel rail.
WARNING: Fuel vapour is highly flammable
and in confined spaces is also explosive
and toxic. Always have a fire extinguisher
containing foam, CO
2, gas or powder close
at hand when handling or draining fuel.
3. Up to 03MY: Remove nut and bolt securing coil
and position coil aside.
4.Connect adaptor LRT-19-006, to pressure
gauge LRT-19-004 .
5.Remove schraeder valve cap.
6.Connect pressure gauge to fuel rail schraeder
valve.
7.Start engine. Pressure at idle = 3.4 bar. If
pressure is below 3.4 bar, suspect the following
in order: fuel hoses, filter, regulator and pump.
Refit
1.Stop engine.
2.Disconnect pressure gauge LRT-19-006 and
adapter LRT-19-004 from fuel rail.
3. Up to 03MY: Fit and tighten nut and bolt
securing coil.
4.Fit acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
Fuel system - pressure test - K1.8
$% 19.50.13
Check
1.Disconnect battery earth lead.
2.Position absorbent cloth beneath fuel pipe to
catch spillage.
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
3.Disconnect fuel pipe from inlet manifold.
4.Connect LRT-19-004A to manifold and fuel
pipe.
Note:: LRT-19-004X can be used as an
alternative.
5.Connect battery earth lead.
6.Start engine. Pressure at idle = 3.6 bar ± 0.2
bar.
7.Stop engine. If pressure is out of tolerance
suspect the following in order: fuel hoses, filter
and pump.
8.Remove plug, reconnect vacuum hose and
secure hose with clip.
9.Disconnect battery earth lead.
10.Disconnect LRT-19-004A from fuel pipe and
inlet manifold.
11.Connect fuel pipe to manifold.
12.Connect battery earth lead.
LRT - 19 -004A
M19 3675

FUEL DELIVERY SYSTEM - PETROL
19-2-34 REPAIRS
Filler neck
$% 19.55.07
Remove
1.Disconnect battery earth lead.
2.Ensure fuel tank is less than half full. If not,
drain fuel tank to less than half full.

+ FUEL DELIVERY SYSTEM -
PETROL, ADJUSTMENTS, Fuel tank - drain.
3.Remove RH rear wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
4.Remove fuel filler cap.
CAUTION: Before disconnecting any part of
the fuel system, it is imperative that all dust,
dirt and debris is removed from around
components to prevent ingress of foreign
matter into fuel system.
5.Unclip escutcheon from fuel filler neck.
WARNING: Fuel vapour is highly flammable
and in confined spaces is also explosive
and toxic. Always have a fire extinguisher
containing foam, CO
2, gas or powder close
at hand when handling or draining fuel.
6.Remove 3 nuts securing fuel filler neck to body.7.Release clip from breather hose and
disconnect breather hose from filler neck.
8.Release fuel tank vent pipe from filler neck.
9.Disconnect Lucar connector from fuel filler
neck.
10.Remove bolt securing filler neck to body.
11.Remove tamper proof cover from filler hose clip
and loosen clip.
12.Disconnect hose from filler neck and remove
filler neck assembly.
Refit
1.Position filler neck assembly, connect to hose,
secure clip and fit tamper proof cover.
2.Fit bolt securing filler neck to body and tighten
to 9 Nm (7 lbf.ft).
3.Connect Lucar connector to fuel filler neck.
4.Position fuel tank vent pipe around filler neck.
5.Connect breather hose to filler neck, fit and
secure clip.
6.Fit nuts securing fuel filler neck to body and
tighten to 9 Nm (7 lbf.ft).
7.Clip escutcheon to fuel filler neck.
8.Fit fuel filler cap.
9.Fit RH rear wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
10.Connect battery earth lead.
M19 3230

FUEL DELIVERY SYSTEM - PETROL
19-2-38 REPAIRS
15.Remove fuel rail and discard 'O' rings
CAUTION: Always fit plugs to open
connections to prevent contamination.
Refit
1.Lubricate new 'O' rings with castor oil and fit to
injectors.
2.Remove plugs from inlet manifolds.
3.Position injector harness to injector protection
cover - if fitted or to bosses on fuel rail fuel rail
and secure with clips.
4.Position injectors and fuel rail to inlet manifolds.
5.Connect multiplugs to injectors.
6.Fit and tighten 4 bolts securing fuel rail to inlet
manifold to 8 Nm (6 lbf.ft).
7. Up to 03MY: Position ignition coils to LH inlet
manifold.
8. Up to 03MY: Position earth lead, fit nuts and
bolts securing ignition coils to LH inlet manifold
and tighten to 9 Nm (7 lbf.ft).
9.Position alternator and secure with nuts and
bolts, tighten to 45 Nm (33 lbf.ft).
10.Using a 3/8" square drive socket bar, raise
ancillary drive belt tensioner and fit drive belt to
pulleys.
11.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
12.Fit inlet manifold chamber.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.
13.Connect battery earth lead.
Injector - KV6
$% 19.60.10
Remove
1.Disconnect battery earth lead.
2.Remove fuel rail.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Fuel rail - KV6 - Non
NAS.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Fuel rail - KV6 - NAS.
3.Remove clip securing injector to fuel rail.
4.Remove injector from fuel rail, remove and
discard 'O' ring from injector.
CAUTION: Always fit plugs to open
connections to prevent contamination.
Refit
1.Clean injector and mating face in fuel rail.
2.Remove cap from new injector and fit to old
injector.
3.Lubricate new 'O' ring with castor oil and fit to
injector.
4.Fit injector to fuel rail and secure with clip.
5.Fit fuel rail.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Fuel rail - KV6 - Non
NAS.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Fuel rail - KV6 - NAS.
6.Connect battery earth lead.

FUEL DELIVERY SYSTEM - PETROL
REPAIRS 19-2-39
Injectors - set - K1.8
$% 19.60.12
Remove
1.Disconnect battery earth lead.
2.Release clip and disconnect vacuum pipe from
fuel pressure regulator.
3.Remove engine oil dipstick.
4.Position absorbent cloth beneath fuel rail.
5.Release fuel feed hose from fuel rail.
CAUTION: Always fit plugs to open
connections to prevent contamination.6.Remove 2 bolts securing fuel rail to inlet
manifold.
7.Release fuel rail and injectors from inlet
manifold.
8.Release and remove injector spacer.
9.Disconnect multiplug from injectors.
10.Remove the fuel rail complete with injectors.
11.Release spring clips securing injectors to fuel
rail and remove fuel injectors.
12.Remove and discard 2 'O' rings from each
injector.
13.Fit protective caps to each end of injectors.

FUEL DELIVERY SYSTEM - PETROL
19-2-40 REPAIRS
Refit
1.Remove protective caps from each injector.
2.Clean injectors and recesses in fuel rail and
inlet manifold.
3.Lubricate new 'O' ring with castor oil and fit to
injector.
4.Fit injectors to fuel rail and secure with spring
clips.
5.Position fuel rail assembly and connect injector
multiplugs.
6.Fit injector spacer.
7.Push each injector into inlet manifold.
8.Fit bolts securing fuel rail to inlet manifold and
tighten to 8 Nm ( 6 lbf.ft).
9.Connect fuel feed hose to fuel rail.
10.Fit engine oil dipstick.
11.Connect vacuum pipe to fuel pressure regulator
and secure with clip.
12.Connect battery earth lead.
Actuator unit - cruise control - KV6 - non
NAS
$% 19.75.05
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Disconnect vacuum hose from actuator.
4.Remove nut securing actuator to mounting
bracket.
5.Release operating rod from throttle cam and
remove actuator.
Refit
1.Position actuator and connect operating rod to
throttle cam.
2.Position actuator into mounting bracket, fit and
tighten nut.
3.Connect vacuum hose to actuator.
4.Check pull rod to retainer clearance, with lever
fully returned, pull rod should just be held by
retainer.
5.Release retainer by turning anti-clockwise,
eliminate clearance then rotate retainer half
turn clockwise. Check pull rod is just held and
rotate retainer a further quarter turn clockwise
to lock.
6.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
7.Connect battery earth lead.