service LAND ROVER FREELANDER 2001 Owner's Manual

GENERAL DATA
04-8
Pistons
Type Aluminium alloy, tin plated, thermal expansion with offset gudgeon pin
Piston diameter:
⇒ Grade A 79.975 - 79.990 mm (3.1486 - 3.1492 in.)
⇒ Grade B 79.991 - 80.005 mm (3.1492 - 3.1498 in.)
Clearance in bore 0.01 - 0.04 mm (0.0004 - 0.0016 in.)
Maximum ovality 0.30 mm (0.012 in.)
Piston rings:
Type: 2 compression, 1 oil control
⇒ Top compression ring Barrel faced, granulite coated
⇒ 2nd compression ring Tapered, phosphate coated
⇒ Oil control ring Nitrided ring with radii and spring
New ring to groove clearance:
⇒ Top compression ring 0.040 - 0.072 mm (0.0016 - 0.0028 in.)
⇒ 2nd compression ring 0.030 - 0.062 mm (0.0012 - 0.0024 in.)
⇒ Oil control ring 0.010 - 0.180 mm (0.0004 - 0.0071 in.)
Ring fitted gap 20 mm (0.75 in) from top of bore:
⇒ Top compression ring 0.20 - 0.35 mm (0.008 - 0.014 in.)
⇒ 2nd compression ring 0.28 - 0.48 mm (0.011 - 0.019 in.)
⇒ Oil control ring 0.15 - 0.40 mm (0.006 - 0.016 in.)
Piston ring width:
⇒ Top compression ring 0.978 - 0.990 mm (0.0385 - 0.0390 in.)
⇒ 2nd compression ring 1.178 - 1.190 mm (0.0464 - 0.0469 in.)
⇒ Oil control ring 0.33 - 0.38 mm (0.0130 - 0.0150 in.)
Camshaft
Type DOHC acting directly on tappets, incorporates target/reluctor for
camshaft sensor
Bearings 6 per camshaft, direct line bored
Drive Toothed belt driven from crankshaft gear, automatically tensioned
Camshaft end-float 0.06 - 0.19 mm (0.002 - 0.007 in.)
⇒ Service limit 0.30 mm (0.012 in.)
Bearing clearance 0.060 - 0.094 mm (0.0024 - 0.0037 in.)
⇒ Service limit 0.15 mm (0.006 in.)
Tappets
Type Self-adjusting lightweight hydraulic tappets, operated directly from
camshafts
Tappet outside diameter 32.959 - 32.975 mm (1.2976 - 1.2982 in.)
Valve timing:
Inlet valves:
⇒ Opens
⇒ Closes
⇒ Maximum lift12° BTDC
52° ABDC
8.8 mm (0.35 in.)
Exhaust valves:
⇒ Opens
⇒ Closes
⇒ Maximum lift52° BBDC
12° ATDC
8.8 mm (0.35 in.) General

GENERAL DATA
04-9
Valves
Stem diameter:
⇒ Inlet valves 5.952 - 5.967 mm (0.2343 - 0.2349 in.)
⇒ Exhaust valves 5.947 - 5.962 mm (0.2341 - 0.2347 in.)
Stem to guide clearance:
⇒ Inlet valves 0.033 - 0.063 mm (0.0013 - 0.0025 in.)
⇒⇒ Service limit 0.07 mm (0.0028 in.)
⇒ Exhaust valves 0.038 - 0.078 mm (0.0015 - 0.0031 in.)
⇒⇒ Service limit 0.11 mm (0.0043 in.)
Valve stem fitted height:
⇒ New 38.93 - 39.84 mm (1.5327 - 1.5685 in.)
⇒ Service limit 40.10 mm (1.5787 in.)
Head diameter:
⇒ Inlet valves 27.6 - 27.8 mm (1.087 - 1.094 in.)
⇒ Exhaust valves 24.0 - 24.2 mm (0.945 - 0.953 in.)
Valve seat width:
⇒ Inlet 1.0 - 1.4 mm (0.039 - 0.055 in)
⇒ Exhaust 1.4 - 1.8 mm (0.055 - 0.071 in)
Seat face angle - Inlet and Exhaust 45°
Valve face angle - Inlet and Exhaust 45°
Valve springs
Free length 50.0 mm (1.97 in.)
Fitted length 37.0 mm (1.46 in.)
Load at fitted length 250 ± 12 N
Load at valve open length 450 ± 18 N
Lubrication
Type Cast aluminium wet sump
Pump type Crankshaft driven, eccentric rotor
⇒ Outer rotor to housing clearance 0.28 - 0.36 mm (0.011 - 0.014 in.)
⇒ Inner rotor tip clearance 0.05 - 0.13 mm (0.002 - 0.005 in.)
⇒ Rotor end-float 0.02 - 0.06 mm (0.001 - 0.002 in.)
Relief valve spring free length 38.90 mm (1.531 in.)
Oil filter Full flow disposable screw-on canister
Pressure at idle (min.)
Pressure at 2500 rev/min (hot)
Relief valve opening pressure
Low oil pressure switch opening pressure100 kPa (14.5 lbf/in
2)
375 kPa (3.75 bar, 54.4 lbf/in2)
410 kPa (59.5 lbf/in2)
20 - 58 kPa (3.0 - 8.5 lbf/in2) General

GENERAL DATA
04-12
Cylinder head
Type Aluminium alloy
Cylinder head gasket * Multi-layer steel
Cylinder head warp:
⇒ Lateral
⇒ Longitudinal0.025 mm (0.001 in)
0.2 mm (0.08 in)
Cylinder head height
Reface height - minimum118.95 - 119.05 mm (4.683 - 4.687 in)
118.95 mm (4.683 in)
Cylinder block
Type Cosworth cast aluminium alloy with bearing ladder bolted to bottom of
block
Cylinder liner type Damp, bottom half stepped - sliding fit into lower part of cylinder block
Cylinder liner bore:
⇒ RED grade A 80.000 - 80.015 mm (3.1496 - 3.1502 in.)
⇒ BLUE grade B 80.015 - 80.030 mm (3.1502 - 3.1508 in.)
Crankshaft
Material / Type Cast spheroidal graphite iron with cold rolled fillets on all journals
except outer mains
Crankshaft end-float
⇒ Service limit0.10 - 0.30 mm (0.004 - 0.012 in.)
0.40 mm (0.016 in.)
Main journal diameter:
⇒ Grade 1 67.743 - 67.749 mm (2.6670 - 2.6673 in.)
⇒⇒ Grade A (Green)
†
⇒⇒ Grade B (Yellow)†
⇒⇒ Grade C (Black)†
⇒ Grade 2 67.737 - 67.743 mm (2.6668 - 2.6670 in.)
⇒⇒ Grade A (Blue)
†
⇒⇒ Grade B (Green)†
⇒⇒ Grade C (Yellow)†
⇒ Grade 3 67.731 - 67.737 mm (2.6666 - 2.6668 in.)
⇒⇒ Grade A (Red)
†
⇒⇒ Grade B (Blue)†
⇒⇒ Grade C (Green)†
Maximum out of round 0.010 mm (0.0004 in.)
Main housing diameter:
⇒ Grade A 71.600 - 71.593 mm (2.8189 - 2.8186 in.)
⇒ Grade B 71.593 - 71.586 mm (2.8186 - 2.8183 in.)
⇒ Grade C 71.586 - 71.579 mm (2.8183 - 2.8181 in.)
Big-end journal diameter:
⇒ Grade A 54.049 - 54.055 mm (2.1279 - 2.1281 in.)
⇒ Grade B 54.043 - 54.049 mm (2.1277 - 2.1279 in.)
⇒ Grade C 54.037 - 54.043 mm (2.1274 - 2.1277 in.)
⇒ Maximum out of round 0.010 mm (0.0004 in.)
Big-end housing diameter:
⇒ Grade 7 57.677 - 57.671 mm (2.2707 - 2.2705 in.)
⇒⇒ Grade A (Green)
*
⇒⇒ Grade B (Blue)*
⇒⇒ Grade C (Red)*
⇒ Grade 8 57.671 - 57.665 mm (2.2705 - 2.2703 in.)
⇒⇒ Grade A (Yellow)
*
⇒⇒ Grade B (Green)*
General

GENERAL DATA
04-14
Clearance in bore 20 mm (0.75 in.) from bottom of
cylinder bore0.034 - 0.035 mm (0.0013 - 0.0014 in.)
Maximum ovality 0.3 mm (0.012 in.)
Piston rings
Type:
⇒ Top compression ring Chrome plated steel
⇒ 2nd compression ring Chrome plated cast iron
⇒ Oil control ring Stainless steel top and bottom rails with expander ring
New ring to groove clearance:
⇒ Top compression ring 0.05 - 0.08 mm (0.0020 - 0.0031 in.)
⇒ 2nd compression ring 0.04 - 0.07 mm (0.0012 - 0.0024 in.)
⇒ Oil control ring 0.010 - 0.180 mm (0.0004 - 0.0071 in.)
Ring fitted gap 20 mm (0.75 in) from top of bore:
⇒ Top compression ring 0.20 - 0.35 mm (0.008 - 0.014 in.)
⇒ 2nd compression ring 0.28 - 0.45 mm (0.011 - 0.018 in.)
⇒ Oil control ring 0.25 - 1.00 mm (0.010 - 0.039 in.)
Piston ring width:
⇒ Top compression ring 3.1 ± 0.15 mm (0.122 ± 0.006 in.)
⇒ 2nd compression ring 3.15 - 3.45 mm (0.124 - 0.136 in.)
⇒ Oil control ring 2.286 - 2.438 mm (0.090 - 0.096 in.)
Camshaft
Type Twin camshafts on each cylinder bank retained by camshaft carrier,
line bored with cylinder head. Reluctor for camshaft sensor mounted
on left hand inlet camshaft
Camshaft identification:
⇒ Inlet Orange paint mark
⇒ Exhaust Blue paint mark
Bearings 5 per camshaft
Drive Toothed belt driven from crankshaft to front of inlet camshafts, 2 x
short toothed belts from rear of inlet camshafts to exhaust camshafts
Camshaft end-float 0.06 - 0.19 mm (0.002 - 0.007 in.)
⇒ Service limit 0.3 mm (0.012 in.)
Bearing clearance 0.025 - 0.059 mm (0.0010 - 0.0023 in.)
⇒ Service limit 0.1 mm (0.004 in.)
Tappets
Type Hydraulic self-adjusting, directly operated from camshafts
Tappet outside diameter 32.959 - 32.975 mm (1.2976 - 1.2982 in.)
Valve timing
Inlet valves:
⇒ Opens
⇒ Closes2° BTDC
54° ABDC
Exhaust valves:
⇒ Opens
⇒ Closes50° BBDC
14° ATDC
Valve maximum lift:
Inlet valves 8.2 mm (0.32 in.)
Exhaust valves 8.8 mm (0.35 in.) General

GENERAL DATA
04-15
* New metal dowels supplied with gasket must be fitted
Valves
Stem diameter:
⇒ Inlet valves 5.952 - 5.967 mm (0.2343 - 0.2349 in.)
⇒ Exhaust valves 5.947 - 5.962 mm (0.2341 - 0.2347 in.)
Stem to guide clearance:
Inlet valves 0.033 - 0.063 mm (0.0013 - 0.0025 in.)
⇒ Service limit 0.07 mm (0.0028 in.)
Exhaust valves 0.038 - 0.078 mm (0.0015 - 0.0013 in.)
⇒ Service limit 0.11 mm (0.0043 in.)
Valve stem fitted height:
⇒ New 38.93 - 39.84 mm (1.533 - 1.569 in.)
⇒ Service limit 40.10 mm (1.579 in.)
Valve guide fitted height 6.0 mm (0.24 in.)
Valve guide inside diameter 6.000 - 6.025 mm (0.2362 - 0.2372 in.)
Head diameter:
⇒ Inlet valves 31.4 - 31.6 mm (1.236 - 1.244 in.)
⇒ Exhaust valves 27.3 - 27.5 mm (1.075 - 1.083 in.)
Valve seat width:
⇒ Inlet valves
⇒ Exhaust valves1.2 mm (0.05 in.)
1.6 mm (0.06 in)
Seat face angle:
⇒ Inlet valves
⇒ Exhaust valves45°
45°
Valve face angle:
⇒ Inlet valves
⇒ Exhaust valves45°
45°
Valve springs
Free length 47.6 mm (1.874 in.)
Fitted length 37.0 mm (1.457 in.)
Load at fitted length 210 ± 13 N
Load at top of lift 440 ± 22 N
Lubrication
Type Cast aluminium, wet sump with full flow filtration
Oil pump: Crankshaft driven, high pressure die cast body
⇒ Outer rotor end-float 0.04 - 0.09 mm (0.0016 - 0.0035 in.)
⇒ Inner rotor end-float 0.04 - 0.09 mm (0.0016 - 0.0035 in.)
⇒ Inner rotor tip 0.05 - 0.13 mm (0.002 - 0.005 in)
⇒ Outer rotor to body diameterical clearance
0.13 - 0.23 mm (0.0051 - 0.0091 in.)
⇒ Rotor body to drive gear clearance (pump not fitted)
0.15 - 0.25 mm (0.0059 - 0.0098 in.)
Relief valve spring free length 38.90 mm (1.531 in)
Oil filter Full-flow disposable cartridge
Oil cooler Partial flow type
Pressure at idle (min.) 1.0 bar (14.5 lbf.in
2)
Pressure at 3000 rev/min. 3.0 bar (43.5 lbf.in
2)
Relief valve opening pressure 4.1 bar (59.5 lbf.in
2)
Low oil pressure switch opening pressure 0.3 - 0.5 bar (4.4 - 7.3 lbf.in
2) General

GENERAL DATA
04-20
Clutch
Type Maintenance free hydraulic system
Pressure plate diameter (all variants) 228 mm (8.976 in.)
Drive plate diameter (all variants) 228 mm (8.976 in.)
Clutch plate friction material Valeo F808
Diaphragm finger height when clamped on a thick
gauge plate28.58 - 31.54 mm (1.125 - 1.242 in.)
Diaphragm finger clearance (service limit) 1.0 mm (0.039 in)
Clutch plate thickness under 6600 N (1484 lb) axial
load:
⇒ New 6.9 - 7.5 mm (0.272 - 0.295 in.)
⇒ Service limit (K1.8/PG1) 5.60 mm (0.220 in.)
⇒ Service limit (Td4/Getrag) 5.60 mm (0.220 in.)
Rivet depth:
⇒ New 1.2 mm (0.047 in.) above rivet head
⇒ Service limit 0.20 mm (0.008 in.) above rivet head
Clutch plate run-out:
⇒ New 0.4 mm (0.016 in.)
⇒ Service limit 0.4 mm (0.016 in.)
Pressure plate warpage (Service limit):
⇒ K1.8 engine with PG1 gearbox 0.18 mm (0.0071 in.)
⇒ Td4 engine with Getrag gearbox 0.18 mm (0.0071 in.)

GENERAL DATA
04-22
Manual Gearbox - PG1
Gear ratios:
⇒ First 3.250 : 1 (19.902 : 1 overall)
⇒ Second 1.894 : 1 (11.598 : 1 overall)
⇒ Third 1.222 : 1 (7.483 : 1 overall)
⇒ Fourth 0.848 : 1 (5.019 : 1 overall)
⇒ Fifth 0.649 : 1 (3.974 : 1 overall)
⇒ Reverse 3.000 : 1
Reverse idler gear to selector fork clearance 0.5 to 1.1 mm (0.020 - 0.043 in)
Selector fork prong width 13.0 to 13.3 mm (0.512 - 0.524 in)
Selector fork groove to pin clearance:
⇒ Standard 0.05 to 0.35 mm (0.002 - 0.014 in)
⇒ Service limit 0.50 mm (0.020 in)
Selector fork groove width 7.05 to 7.25 mm (0.278 - 0.285 in)
Gearshift arm to guide clearance:
⇒ Standard 0.20 to 0.30 mm (0.008 - 0.012 in)
⇒ Service limit 0.55 mm (0.022 in)
Interlock shift guide groove width 8.10 to 8.20 mm (0.319 - 0.323 in)
Synchro ring to gear clearance:
⇒ Standard 0.85 to 1.10 mm (0.033 - 0.043 in)
⇒ Service limit (minimum clearance) 0.40 mm (0.016 in)
Selector shaft forks in synchro sleeve grooves
clearance:
⇒ Standard 0.45 to 0.65 mm (0.018 - 0.026 in)
⇒ Service limit 1.00 mm (0.039 in)
Gearshift arm guide to selector fork clearance:
⇒ Standard 0.20 to 0.50 mm (0.008 - 0.020 in)
⇒ Service limit 0.80 mm (0.031 in)
Gearshift arm guide tongue width 11.90 to 12.00 mm (0.469 - 0.472 in)
Gearshift arm guide to interlock assembly clearance:
⇒ Standard 0.05 to 0.35 mm (0.002 - 0.014 in)
⇒ Service limit 0.60 mm (0.024 in)
Gearshift arm guide groove width 13.05 to 13.25 mm (0.514 - 0.522 in)
Interlock ball to gearshift arm guide clearance:
⇒ Standard 0.05 to 0.25 mm (0.002 - 0.010 in)
⇒ Service limit 0.50 mm (0.020 in)
Interlock ball outside diameter 12.05 to 12.15 mm (0.474 - 0.478 in)
2nd to 3rd gear clearance:
⇒ Standard 0.06 to 0.21 mm (0.002 - 0.008 in)
⇒ Service limit 0.30 mm (0.012 in)
3rd gear thickness:
⇒ Standard 35.42 to 35.47 mm (1.394 - 1.396 in)
⇒ Service limit 35.30 mm (1.390 in)

GENERAL DATA
04-23
4th to 5th gear clearance:
⇒ Standard 0.06 to 0.21 mm (0.002 - 0.008 in)
⇒ Service limit 0.30 mm (0.012 in)
Spacer collar length:
⇒ Standard 26.03 to 26.08 mm (1.025 - 1.027 in)
⇒ Service limit 26.01 mm (1.024 in)
4th gear thickness:
⇒ Standard 30.92 to 30.97 mm (1.217 - 1.219 in)
⇒ Service limit 30.80 mm (1.213 in)
5th gear thickness:
⇒ Standard 30.42 to 30.47 mm (1.198 - 1.200 in)
⇒ Service limit 30.30 mm (1.193 in)
1st. gear to thrust washer clearance:
⇒ Standard 0.03 to 0.08 mm (0.0012 - 0.0031 in)
⇒ Service limit 0.18 mm (0.007 in)
2nd to 3rd gear clearance 0.03 to 0.10 mm (0.0012 - 0.0039 in)
Input shaft end thrust 0.14 to 0.21 mm (0.006 - 0.008 in)

GENERAL DATA
04-31
Brakes
Front disc brakes
Type Pin-slider caliper with ventilated disc, self-adjusting
Disc diameter 262 mm (10.31 in)
Disc thickness:
⇒ New
⇒ Service limit20.8 - 21.00 mm (0.818 - 0.826 in)
18.00 mm (0.708 in)
Disc run-out (maximum) 0.040 mm (0.0016 in), with wheel on
Pad minimum thickness 3.00 mm (0.118 in)
Rear drum brakes
Drum inside diameter 254 mm (10.00 in)
Drum wear limit 255.49 mm (10.059 in), discard drum
Lining minimum thickness 2.00 mm (0.079 in)
Drum ovality limit 0.012 mm (0.0005 in)
Master cylinder
Bore diameter 23.80 mm (0.937 in)
Brake servo
Servo boost ratio 4.5 : 1
Parking brake
Type Mechanically operated via twin cables on rear drum brakes
Anti-lock braking system
Circuit type Diagonal split, dual circuit, 4-sensor ABS
ABS type TEVES MK20 with ABS, Hill Descent Control (HDC), Electronic
Traction Control (ETC) and Electronic Brakeforce Distribution (EBD)

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, )