warning LAND ROVER FREELANDER 2001 Repair Manual

FUEL DELIVERY SYSTEM - PETROL
19-2-32 REPAIRS
Tank - NAS
$% 19.55.01
Remove
1.Position vehicle on ramp.
2.Disconnect battery earth lead.
3.Using a fuel recovery appliance, drain the fuel
from the tank into a sealed container. Follow
the manufacturer's instructions for the
connection and safe use of the appliance.

+ FUEL DELIVERY SYSTEM -
PETROL, ADJUSTMENTS, Fuel tank - drain.
WARNING: The fuel tank must be drained
before it is removed from the vehicle.
4.Remove intermediate exhaust pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Intermediate
pipe - NAS.
5.Remove propeller shaft.

+ DRIVESHAFTS, REPAIRS, Propeller
shaft assembly.
6.Remove RH rear wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
7.Remove tamper proof cover from filler hose clip
and loosen clip.8.Support weight of rear subframe and remove 4
bolts securing subframe to body.
9.Lower subframe.
CAUTION: Do not allow sub frame to hang
on rear brake hoses.
10.With assistance, remove 4 bolts securing fuel
tank to body and remove tank.
NOTE: Pull vent and breather hoses through
body while lowering fuel tank.

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

COOLING SYSTEM - K SERIES KV6
ADJUSTMENTS 26-3-1
COOLING SYS TEM - K SER IES KV6 ADJUST ME NTS
Coolant - drain and refill
$% 26.10.01
Drain
1.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
2.Visually check engine and cooling system for
signs of coolant leaks.
WARNING: Since injury such as scalding
could be caused by escaping steam or
coolant, do not remove the filler cap from
the coolant expansion tank while the
system is hot.
3.Examine hoses for signs of cracking, distortion
and security of connections.
4.Remove expansion tank filler cap.
5.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
6.Position container to collect coolant.
7.Remove cylinder block drain plug.
8.Release clip and remove bottom hose from
radiator.
9.Allow cooling system to drain.Refill
1.Flush system with water under low pressure.
Do not use water under high pressure as it
could damage the radiator.
2.Clean cylinder block drain plug and apply
sealant, Part No. STC 50552 to first 3 threads.
3.Fit cylinder block drain plug and tighten to 20
Nm (15 lbf.ft).
4.Fit bottom hose to radiator and secure with clip.
5.Prepare coolant to required concentration.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Fluids.
6.Remove bleed screw from heater return hose.
7.Slowly fill the system through the coolant
expansion tank until a steady flow of coolant is
emitted from the bleed hole.
8.Fit and close bleed screw in heater return hose.
9.Continue to fill system through the expansion
tank until coolant reaches to the base of the
expansion tank bleed hose.
10.Fit expansion tank filler cap.
11.Start and run engine at idle speed for 5
minutes.
CAUTION: DO NOT operate air conditioning
12.Switch off engine.
13.Squeeze bottom hose several times to remove
any trapped air.
14.Start engine and run at speeds varying
between idle speed and 3500 rev/min for 7
minutes.
15.Switch off engine and allow to cool.
16.Remove expansion tank filler cap and add
coolant until it reaches the 'MAX' mark on the
expansion tank.
17.Fit expansion tank filler cap.
18.Start and run engine until normal operating
temperature is reached.
CAUTION: The bottom hose must be warm/
hot, this will ensure the thermostat is fully
open.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-6 REPAIRS
Tail pipe & silencer
$% 30.10.22
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Loosen tail pipe clamp nut.
3.Release 2 rubber mountings from tail pipe.
4.Remove tail pipe.Refit
1.Clean mating faces of tail pipe and intermediate
pipe.
2.Fit tail pipe and connect rubber mountings.
3.Tighten tail pipe clamp nut to 55 Nm (41 lbf.ft).
4.Remove stands and lower vehicle.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-13
13.Remove 4 nuts securing manifold and remove
exhaust manifold.
14.Remove and discard manifold and down pipe
gaskets.
Refit
1.Clean exhaust manifold and mating faces.
2.Using new gaskets, fit exhaust manifold and
tighten nuts to cylinder head to 45 Nm (33 lbf.ft)
and nuts to front pipe to 50 Nm (37 lbf.ft).
3.Connect H02S multiplugs, secure multiplugs to
brackets and harness to clips.
4.Clean compressor and mounting bracket
mating faces.
5.Fit compressor heat shield.
6.Position compressor to mounting and align
heat shield. Fit and tighten bolts to 25 Nm (18
lbf.ft).
7.Using a 3/8" square drive socket bar, raise
ancillary drive belt tensioner and fit drive belt to
pulleys.
8.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
9.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
10.Connect battery earth lead.
Seals - inlet manifold chamber - up to
03MY
$% 30.15.37
Remove
1.Disconnect battery earth lead.
2.Remove vacuum enhancer.

+ BRAKES, REPAIRS, Vacuum -
enhancer - KV6.
3.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.
4.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.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-18 REPAIRS
Seals - inlet manifold chamber - from
03MY
$% 30.15.37
Remove
1.Disconnect battery earth lead.
2.Remove vacuum enhancer.

+ BRAKES, REPAIRS, Vacuum -
enhancer - KV6.
3.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.
4.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.
5.Release and disconnect EVAP hose from
purge control valve.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Disconnect multiplug from purge control valve.7. Non NAS models: Disconnect small vacuum
pipe from purge control valve.
8. Non NAS models: Depress locking collar and
release vacuum pipe from IACV housing.
CAUTION: Always fit plugs to open
connections to prevent contamination.
9. Non NAS models: Disconnect multiplug from
IACV.
10. Non NAS models: Disconnect multiplug from
TP sensor.
11. Non NAS models: Depress locking collars and
release vacuum/breather pipe from purge
control valve and LH camshaft cover. Release
clip securing hose to 'T' piece and remove pipe.
CAUTION: Always fit plugs to open
connections to prevent contamination.
M30 1171

INTERMEDIATE REDUCTION DRIVE
ADJUSTMENTS 41-1
INTERMEDIATE RE DUCTION DRIVE ADJUST ME NTS
Intermediate reduction drive (IRD) fluid -
drain & refill - Non NAS
$% 41.25.06
Drain
1.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
2.Place container beneath IRD unit.
WARNING: Observe due care when draining
gearbox fluid as the fluid can be very hot.
3.Clean area around filler/level and drain plugs.
4.Remove filler/drain plugs and discard sealing
washers. Allow fluid to drain.
NOTE: The fluid should be drained with the
transmission at normal operating temperature.
5.Fit new sealing washer and tighten drain plug to
35 Nm (26 lbf.ft).Refill
1.Fill with correct fluid until it just runs from filler/
level hole. Allow sufficient time for fluid to flow
and reach a common level in unit.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
2.Fit new sealing washer and tighten filler/level
plug to 35 Nm (26 lbf.ft).
3.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.

INTERMEDIATE REDUCTION DRIVE
41-2 ADJUSTMENTS
Intermediate reduction drive (IRD)
lubrication system - drain & refill - NAS
$% 41.25.06
Drain
1.Remove underbelly panel

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
2.Place container beneath IRD unit.
WARNING: Observe due care when draining
gearbox fluid as the fluid can be very hot.
3.Clean area around filler/level and drain plugs.
4.Using LRT-41-021 remove filler plug and
discard sealing washer.5.Remove drain plug, discard sealing washer and
allow oil to drain.
NOTE: The fluid should be drained with the
transmission at normal operating temperature.
6.Fit new sealing washer and tighten drain plug to
35 Nm (26 lbf.ft).
Refill
1.Fill with fluid until it just runs from filler/level
hole. Allow sufficient time for fluid to flow and
reach a common level in unit.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
2.Fit new sealing washer and tighten filler/level
plug to 35 Nm (26 lbf.ft).
3.Fit underbelly panel

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
M417853
LRT-41-021
M41 7687

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-3
REPAIRS
Intermediate reduction drive (IRD) unit -
Td4
$% 41.25.01.99
Remove
1.Disconnect battery earth lead.
2.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
3.Remove rear beam.

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

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - front.
5.Drain fluid from IRD.

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

+ MANUAL GEARBOX - GETRAG,
ADJUSTMENTS, Gearbox oil - drain and
refill.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
7.Remove 3 bolts securing RH splash shield to
body and remove shield.8.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release drive shaft from
IRD.
9.With assistance, pull hub outwards and release
drive shaft from IRD.
10.Remove and discard drive shaft circlip.
11.Reference mark front propeller shaft for
reassembly.
12.Raise one rear wheel for rotation of propeller
shaft to access bolts.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-25
Seal - driveshaft - RH
$% 41.29.09
Remove
1.Remove RH drive shaft.

+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - RH.
2.Carefully remove and discard oil seal, take care
not to damage oil seal recess.
Refit
1.Clean oil seal recess.
2.Locate seal on tool LRT-37-031 and replacer
LRT-37-027 with sealing lip facing towards
housing.
3.Carefully drift oil seal into housing until fully
seated in recess.
4.Fit RH drive shaft.

+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - RH.
Seal - pinion gear housing - Td4
$% 41.29.11
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Drain fluid from IRD.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
4.Raise one rear wheel for rotation of propeller
shaft to access bolts.
5.Reference mark front propeller shaft for
reassembly.
6.Remove 6 nuts and bolts securing propeller
shaft to IRD drive flange.
7.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.