gearbox LAND ROVER FREELANDER 2001 Owner's 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
09-3
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.

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
09-4
Sealants
The following table lists those sealants which are
used during repair / overhaul procedures covered in
this manual; it is essential that the sealant specified
for a particular procedure is used at all times.
Component Application Land Rover
Part No.
Td4 Engine Camshaft cover
gasket joint linesSTC 50550
Td4 Engine Sump gasket joint
linesSTC 50550
K 1.8 Engine Oil pressure switch
threadsSTC 50552
K 1.8 Engine Oil pressure relief
valve plug threadsSTC 50552
K 1.8 Engine Oil temperature
sensor threadsSTC 50552
K 1.8 Engine Oil pump cover
plate screwsSTC 50552
K 1.8 Engine Camshaft carrier to
cylinder headSTC 4600
K 1.8 Engine Bearing ladder to
cylinder blockSTC 4600
K 1.8 Engine Sump to bearing
ladderSTC 4600
K 1.8 Engine Oil rail to bearing
ladderSTC 4600
K 1.8 Engine Crankshaft rear oil
seal STC 50550
K 1.8 Engine Cylinder liners to
cylinder blockRTC 3347
KV6 Engine Camshaft timing
belt backplate
cover boltsSTC 50552
KV6 Engine Oil pressure relief
valve plug threadsSTC 50552
KV6 Engine Oil pump cover
plate screwsSTC 50552
KV6 Engine Camshaft carrier to
cylinder headSTC 4600
KV6 Engine Sump to lower
crankcaseSTC 4600
KV6 Engine Oil pick-up strainer
boltSTC 50552
KV6 Engine Lower crankcase to
cylinder blockSTC 50550
KV6 Engine Cylinder liners to
cylinder blockRTC 3347
KV6 Engine Coolant stub pipe to
cylinder blockSTC 50554
Engine
Management
System -
MEMSSensor - Engine
Coolant
temperature (ECT)STC 50552
Cooling
System - KV6Cylinder block drain
plugSTC 50552
Manual
Gearbox - PG12 top bolts -
gearbox to engineSTC 50552
Manual
Gearbox -
GetragRear cover to
gearcaseSTC 4600
Manual
Gearbox -
GetragGearshift cover STC 4600
Intermediate
Reduction
DriveEnd cover gasket -
IRD housingSTC 4600
Automatic
Gearbox -
JatcoFluid pan to
gearcaseSTC 4600
Rear Axle and
Final DriveDifferential cover to
casingSTC 3811

MAINTENANCE
10-18 MAINTENANCE
Intermediate Reduction Drive - NAS
models
Check and Top-up Fluid
1.With vehicle on a ramp at a convenient working
height, using LRT-41-021, carefully remove
IRD level plug and collect sealing washer.
2.Top-up, if required, until fluid just runs from
hole. Allow sufficient time for oil to flow until it
reaches a common level in unit.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Fluids.
3.Refit level plug to IRD unit using a new sealing
washer.
Manual Gearbox – PG1
Check and Top-up Fluid
WARNING: Avoid excessive skin contact
with mineral oil. Mineral oils remove the
natural fats from the skin, leading to
dryness, irritation and dermatitis.
1.With vehicle on a ramp at a convenient working
height, carefully remove gearbox level plug and
collect sealing washer.
2.Check oil level. Before topping up oil level,
check for visible signs of leakage. Pay
particular attention to drive shaft oil seal.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
3.Refit level plug to gearbox using a new sealing
washer.
M417853
LRT-41-021

MAINTENANCE
MAINTENANCE 10-19
Manual Gearbox – GETRAG
Replace Fluid
WARNING: Avoid excessive skin contact
with mineral oil. Mineral oils remove the
natural fats from the skin, leading to
dryness, irritation and dermatitis.
1.Replace gearbox fluid.

+ MANUAL GEARBOX - GETRAG,
ADJUSTMENTS, Gearbox oil - drain and
refill.
Automatic Gearbox – JATCO
Check and top-up fluid
WARNING: Avoid excessive skin contact
with mineral oil. Mineral oils remove the
natural fats from the skin, leading to
dryness, irritation and dermatitis.
1.Position vehicle on ramp.
2.Apply handbrake and position chocks under
front and rear wheels.
3.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
4.Connect TestBook/T4 to monitor gearbox fluid
temperature.
CAUTION: The gearbox fluid level must only
be checked when the temperature of the
fluid is between 35° and 45°. The reading
obtained will be incorrect if the fluid is
outside this temperature range.
5.Start engine, move selector lever from 'P'
through all gear positions, pausing in each gear
position for 2-3 seconds and return to 'P'
position.
6.Clean area around level plug.
7.With the engine still running, remove level plug
using a 5 mm Allen socket and allow any
excess fluid to drain off.
CAUTION: There are a number of similar
fixings/plugs on the underside of the
gearbox. It is imperative that the correct
plug is removed prior to checking the level.
Removing the wrong fixing/plug could
result in internal damage to the gearbox.
8.If no fluid loss is apparent when level plug is
removed:

MAINTENANCE
MAINTENANCE 10-29
Gear Change and Parking Pawl Engagement –
(Automatic only, normal driving conditions)
1.Select 'R' and check for smooth take up.
2.Select 'D' and check for smooth up-changes of
ratio from rest.
3.Slow down vehicle and check for smooth down-
changes of ratio.
4.Stop vehicle on a slope.
5.Select 'P' and release handbrake.
6.Check that vehicle does not move and that
selector does not slip out of 'P'.
7.Carry out a similar check with vehicle facing in
the opposite direction.
Steering
1.With vehicle stationary, turn steering from lock
to lock. Check for smooth operation and ensure
there is no undue noise from the power steering
pump or drive belt.
Suspension
1.Check for noise, irregularity in ride (e.g.
dampers) and wheel imbalance.
Foot brake
1.Check for pedal effort, travel, braking
efficiency, pulling and binding.
Handbrake
1.Apply handbrake firmly, check travel and
ratchet hold and release.
Instruments
1.Check for correct operation of all instruments
and warning devices where practical.
Body
1.Check for abnormal body noise.
Seat Belts
1.Check for operation of inertia reels.Road Test
1.Drive vehicle on a short road test. Check all
vehicle systems for correct operation. Pay
particular attention to:
lEngine noise
lGearbox noise
lSuspension noise
lBody noise
lBraking system operation
lGear selection
lEngine performance
2.Where possible, check for correct operation of
Hill Descent Control (HDC) system. This should
not be carried out if excessive journey time is
required.
3.After road test, carry out a final inspection of the
vehicle on vehicle ramps.
4.Check all underbonnet fluid levels and top-up if
necessary.

ENGINE - K SERIES KV6
REPAIRS 12-3-25
Cover - engine acoustic
$% 12.30.50
Remove
1.Loosen clip and disconnect fresh air intake
hose from acoustic cover.
2. Non NAS: Loosen clip and release air intake
and air bypass hose from throttle body.
3. NAS:Loosen clip and disconnect air intake
hose from air flow meter (MAF) sensor.
4.Release 2 turnbuckles securing acoustic cover
to LH camshaft cover.
5.Release retaining strap and remove acoustic
cover.
Refit
1.Fit and secure engine acoustic cover.
2.Connect air intake and air bypass hoses,
secure clip.
3.Connect fresh air intake hose to acoustic cover
and tighten clip screw.
Engine and automatic gearbox - up to
03MY
$% 12.37.01.99
Remove
1.Disconnect battery earth lead.
2.Tie bonnet back in upright position.
3.Drain cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
4.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
5.Remove battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
6.Remove engine ECM.

+ ENGINE MANAGEMENT SYSTEM -
SIEMENS, REPAIRS, Engine control module
(ECM) - Non NAS.
7.Remove 2 screws securing harness clamp and
remove clamp.
8.Disconnect 2 engine harness to main harness
multiplugs.

ENGINE - K SERIES KV6
REPAIRS 12-3-27
18.Disconnect Lucar from starter solenoid.
19.Release 2 gearbox harness multiplugs from
mounting bracket clips and disconnect
multiplugs.20.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.
21.Pull back rubber sleeve on fuel pipe connector,
release connector and disconnect fuel pipe
from fuel rail pipe.
CAUTION: Always fit plugs to open
connections to prevent contamination.
22.Release clip and disconnect hose from purge
control valve.
CAUTION: Always fit plugs to open
connections to prevent contamination.
23.Release throttle cable from clips on harness
brackets, if fitted, if fitted.
24.Release throttle cable from abutment bracket
and disconnect cable from throttle body cam, if
fitted.

ENGINE - K SERIES KV6
REPAIRS 12-3-29
33.With an assistant depressing the brake pedal,
remove and discard LH and RH drive shaft
nuts.
34.Remove rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
35.Remove exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - Non
NAS.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - NAS.
36.Raise one rear wheel for rotation of propeller
shaft to access bolts.
37.Reference mark position of viscous coupling
flange to IRD unit flange to aid reassembly.
38.Remove 6 nuts and bolts securing propeller
shaft to IRD drive flange.
39.Release propeller shaft from IRD drive flange
and tie shaft aside.
CAUTION: Care must be taken to support
the Tripode joint when removed from the
IRD unit. To avoid damage to gaiter or steel
can, the joint should not be allowed to fully
extend or be dropped.40.Drain gearbox fluid.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
41.Drain fluid from IRD.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
42.Remove 6 bolts securing RH and LH front
splash shields and remove shields.
43.Remove clips securing brake hoses to RH and
LH damper brackets.
44.Release ABS sensor leads from bracket.
45.Release ABS sensors from RH and LH front
hubs.
M12 6614

ENGINE - K SERIES KV6
12-3-30 REPAIRS
46.Remove nuts securing RH and LH track rod
end ball joints.
47.Fit an M12 nut to each ball pin, flush with end of
each pin.
48.Using LRT-57-043, separate ball pins from RH
and LH steering arms. Remove M12 nuts and
release ball pins from steering arms.
49.Pull RH and LH hubs outwards and release
driveshafts from hubs.
50.Using LRT-54-026, release drive shafts from
IRD unit and gearbox.51.Remove nut securing selector lever to selector
shaft on gearbox and release lever from
selector shaft.
52.Release clip securing selector cable to gearbox
bracket, remove cable and tie aside.
53.Using a 3/8” square drive socket bar, raise
ancillary drive belt tensioner and release drive
belt from A/C compressor pulley.
54.Disconnect multiplug from A/C compressor.