ESP LAND ROVER FREELANDER 2001 Workshop Manual

GENERAL INFORMATION
03-3
Brake hydraulics
Observe the following recommendations when
working on the brake system:
lAlways use two spanners when loosening or
tightening brake pipe or hose connections.
lEnsure that hoses run in a natural curve and are
not kinked or twisted.
lFit brake pipes securely in their retaining clips
and ensure that the pipe run cannot contact a
potential chafing point.
lContainers used for hydraulic brake fluid must
be kept absolutely clean.
lDo not store hydraulic brake fluid in an unsealed
container, it will absorb water and in this
condition would be dangerous to use due to a
lowering of its boiling point.
lDo not allow hydraulic brake fluid to be
contaminated with mineral oil, or put new
hydraulic brake fluid in a container which has
previously contained mineral oil.
lDo not re-use hydraulic brake fluid previously
removed from the system.
lAlways use clean brake fluid or a recommended
alternative to clean hydraulic components.
lFit a blanking cap to a hydraulic union and a
plug to its socket, immediately after
disconnection of pipes and hoses to prevent the
ingress of dirt.
lAbsolute cleanliness must be observed when
working with hydraulic components.
lIt is imperative that the correct brake fittings are
used and that threads of components are
compatible.
Cooling system caps and plugs
Extreme care is necessary when removing engine
cooling system expansion tank caps and coolant
drain or bleed screws when the engine is hot, and
especially if it is overheated.
To avoid the possibility of scalding allow the engine
to cool before attempting coolant cap or plug
removal.
Environmental Precautions
General
This section provides general information which can
help to reduce adverse environmental impacts
incurred through the activities carried out in
workshops.
Emissions to air
Many of the activities that are carried out in
workshops emit gases and fumes which contribute to
global warming, depletion of the ozone layer and/or
the formation of photo-chemical smog at ground
level. By considering and controlling how the
workshop activities are carried out, these gases and
fumes can be minimised, thus reducing the damage
to the environment.
Exhaust fumes
Running car engines is an essential part of workshop
activities and exhaust fumes need to be ventilated to
atmosphere. However, the amount of time engines
are running and the position of the vehicle should be
carefully considered at all times, to reduce the
release of poisonous gases and minimise the
inconvenience to people living nearby.
Solvents
Some of the cleaning agents used are solvent based
and will evaporate to atmosphere if used carelessly,
or if cans are left unsealed. All solvent containers
should be firmly closed when not needed and solvent
should be used sparingly. Suitable alternative
materials may be available to replace some of the
commonly used solvents. Similarly, many paints are
solvent based and the spray should be minimised to
reduce solvent emissions.
Refrigerant
It is illegal to release any refrigerants into the
atmosphere. Discharge and replacement of these
materials from air conditioning units should only be
carried out using the correct equipment.
Checklist
Always adhere to the following:
Engines –
ldon't leave engines running unnecessarily;
lminimise testing times and check where the
exhaust fumes are being blown.

GENERAL INFORMATION
03-6
Waste Management
One of the major ways that pollution can be reduced
is by the careful handling, storage and disposal of all
waste materials that occur on sites. Legislation
makes it illegal to dispose of waste materials other
than to licensed waste carriers and disposal sites.
This means that it is necessary to not only know what
the waste materials are, but also to have the
necessary documentation and licenses.
Handling and storage of waste
Ensure that waste materials are not poured down the
drain or onto soils. They should be stored in such a
way as to prevent the escape of material to land,
water or air.
They must also be segregated into different types of
waste e.g. oil, metals, batteries, used vehicle
components. This will prevent any reaction between
different materials and assist in disposal.
Disposal of waste
Disposal of waste materials must only be to waste
carriers who are licensed to carry those particular
waste materials and all the necessary
documentation must be completed. The waste
carrier is responsible for ensuring that the waste is
taken to the correct disposal sites.Dispose of waste in accordance with the following
guidelines:
lFuel, hydraulic fluid, anti-freeze and oil –
keep separate and dispose of to specialist
contractor.
lRefrigerant – collect using specialist
equipment and containers, and reuse.
lDetergents – safe to pour down the foul drain
if diluted.
lPaint, thinners – keep separate and dispose of
to specialist contractor.
lComponents – send back to supplier for
refurbishment, or disassemble and reuse any
suitable parts. Dispose of the remainder in
ordinary waste.
lSmall parts – reuse any suitable parts, dispose
of the remainder in ordinary waste.
lMetals – can be sold if kept separate from
general waste.
lTyres – keep separate and dispose of to
specialist contractor.
lPackaging – compact as much as possible and
dispose of in ordinary waste.
lAsbestos-containing – keep separate and
dispose of to specialist contractor.
lOily and fuel wastes (e.g. rags, used spill kit
material) – keep separate and dispose of to
specialist contractor.
lAir filters – keep separate and dispose of to
specialist contractor.
lRubber/plastics – dispose of in ordinary
waste.
lHoses – dispose of in ordinary waste.
lBatteries – keep separate and dispose of to
specialist contractor.
lAirbags (explosives) – keep separate and
dispose of to specialist contractor.
lElectrical components – send back to
supplier for refurbishment, or disassemble and
reuse any suitable parts. Dispose of the
remainder in ordinary waste.
lElectronic components – send back to
supplier for refurbishment, or disassemble and
reuse any suitable parts. Dispose of the
remainder in ordinary waste.
lCatalysts – can be sold if kept separate from
general waste.
lUsed spill-absorbing material – keep
separate and dispose of to specialist contractor.
lOffice waste – recycle paper and toner/ink
cartridges, dispose of the remainder in ordinary
waste.

GENERAL INFORMATION
03-15
Fuel System Hoses
All fuel hoses are made up of two laminations, an
armoured rubber outer sleeve and an inner viton
core. If any of the fuel system hoses have been
disconnected, it is imperative that the internal bore is
inspected to ensure that the viton lining has not
become separated from the armoured outer sleeve.
A new hose must be fitted if separation is evident.
Cooling system hoses
The following precautions MUST be followed to
ensure that integrity of cooling hoses and their
connections to system components are maintained.
Hose orientation and connection
Correct orientation of cooling hoses is important in
ensuring that the hose does not become fatigued or
damaged through contact with adjacent
components.
Where 'timing' marks (2) are provided on the hose
and corresponding connection, these must be used
to ensure correct orientation.Hoses must be pushed fully onto their connection
points. Usually, a moulded form (3) on the stub pipe
provides a positive indicator.
Hose clips
Markings (4) are usually provided on the hose to
indicate the correct clip position. If no markings are
provided, position the clip directly behind the
retaining lip at the end of the stub as shown.
Worm drive clips should be oriented with the crimped
side of the drive housing (5) facing towards the end
of the hose, or the hose may become pinched
between the clip and the stub pipe retaining lip.
Worm drive clips should be tightened to 3 Nm (2
lbf.ft) unless otherwise stated.
Ensure that hose clips do not foul adjacent
components.

GENERAL INFORMATION
03-20
Disciplines
Switch off the ignition prior to making any connection
or disconnection in the system, to prevent electrical
surges caused by disconnecting 'live' connections
damaging electronic components.
Ensure hands and work surfaces are clean and free
of grease, swarf, etc. Grease collects dirt which can
cause electrical tracking (short-circuits) or high-
resistance contacts.
When handling printed circuit boards, treat with care
and hold by the edges only; note that some electronic
components are susceptible to body static.
Connectors should never be subjected to forced
removal or refit, especially inter-board connectors.
Damaged contacts can cause short-circuit and
open-circuit fault conditions.
Prior to commencing test, and periodically during a
test, touch a good vehicle body earth to discharge
static charge. Some electronic components are
vulnerable to the static electricity that may be
generated by the operator.
Grease for electrical connectors
Some under bonnet and under body connectors may
be protected against corrosion by the application of a
special grease during vehicle production. Should
connectors be disturbed in service, or repaired or
replaced, additional grease should be re-applied:
Part No. BAU 5811, available in 150 gm tubs.
NOTE: The use of greases other than BAU 5811
must be avoided as they can migrate into relays,
switches etc. contaminating the contacts and leading
to intermittent operation or failure.
Supplementary restraint system
precautions
General
The Supplementary Restraint System (SRS)
provides active protection for vehicle occupants in
the event of a serious collision. The system
components include airbags and pre-tensioner seat
belts which are automatically deployed when a
severe frontal crash condition is detected.
The SRS pyrotechnic components could be
potentially hazardous to the service engineer if not
handled correctly. The following guidelines are
intended to alert the service engineer to potential
sources of danger and emphasise the importance of
ensuring the integrity of SRS components fitted to
the vehicle.
In order to assure system integrity, it is essential that
the SRS system is regularly checked and maintained
so that it is ready for operation in the event of an
accident.
Where necessary, additional specific precautions are
detailed in the relevant sections of this Manual which
should be referred to prior to commencing repair
operations.
WARNING: Always follow the 'SRS Precautions'
and the correct procedures for working on SRS
components. Persons working on SRS systems
must be fully trained and have been issued with
copies of the Safety guidelines.
WARNING: It is imperative that before any work
is undertaken on the SRS system the appropriate
information is read thoroughly.
WARNING: The airbag module contains sodium
azide which is poisonous and extremely
flammable. Contact with water, acid or heavy
metals may produce harmful or explosive
compounds. Do not dismantle, incinerate or
bring into contact with electricity, before the unit
has been deployed.
WARNING: Always replace a seat belt assembly
that has withstood the strain of a severe vehicle
impact, or if the webbing shows signs of fraying.
WARNING: Always disconnect the vehicle
battery before carrying out any electric welding
on a vehicle fitted with an SRS system.
CAUTION: Do not expose an airbag module or
seat belt pre-tensioner to heat exceeding 85º C
(185º F).

GENERAL INFORMATION
03-29
Air conditioning system precautions
General
The air conditioning system contains fluids and
components which could be potentially hazardous to
the service engineer or the environment if not
serviced and handled correctly. The following
guidelines are intended to alert the service engineer
to potential sources of danger and emphasise the
importance of ensuring the integrity of the Air
Conditioning operating conditions and components
fitted to the vehicle.
Where necessary, additional specific precautions are
detailed in the relevant sections of this Manual which
should be referred to prior to commencing repair
operations.
The refrigerant used in the air conditioning system is
HFC-134a (Hydrofluorocarbon) R134a. Always
adhere to the following precautions:
WARNING: Servicing must only be carried out by
personnel familiar with both the vehicle system
and the charging and testing equipment. All
operations must be carried out in a well
ventilated area away from open flame and heat
sources.
WARNING: Do not allow a refrigerant container to
be heated by direct flame or to be placed near
any heating appliance. A refrigerant container
must not be heated above 50
°C.
Do not leave a container of refrigerant without its
cap fitted. Do not transport a container of
refrigerant that is unrestrained, especially in the
boot of a car.
WARNING: Do not smoke or weld in areas where
R134a is in use. Inhalation of concentrations of
vapour can cause dizziness, disorientation,
incoordination, narcosis, nausea or vomiting.
R134a is odourless and colourless. Do not
handle or discharge in an enclosed area, or any
area where the vapour and liquid can come in
contact with a naked flame or hot metal. R134a is
not flammable but can cause a highly toxic gas.
WARNING: Do not allow fluids other than R134a
or compressor lubricant to enter the air
conditioning system. Spontaneous combustion
may occur.WARNING: R134a is a hazardous liquid and when
handled incorrectly can cause serious injury.
Suitable protective clothing, consisting of face
protection, heat proof gloves, rubber boots and
rubber apron or waterproof overalls, must be
worn when carrying out operations on the air
conditioning system.
WARNING: Due to its low evaporating
temperature, R134a must be handled with care.
R134a splashed on any part of the body will
cause immediate freezing of that area. Also,
refrigerant cylinders and replenishment trolleys
when discharging will freeze skin to them if
contact is made.
WARNING: Under no circumstances should
refrigerant hoses be disconnected without first
discharging the system.
Do not disconnect any pipes in an air
conditioning refrigeration system unless trained
and instructed to do so. A refrigerant is used
which can cause blindness if allowed to contact
eyes.
WARNING: Refrigerant must always be recycled
before re-use to ensure that the purity of the
refrigerant is high enough for safe use in the air
conditioning system.
Recycling should always be carried out with
equipment which is design certified by
Underwriter Laboratory Inc. for compliance with
SAE J1991. Other equipment may not recycle
refrigerant to the required level of purity.
A R134a Refrigerant Recovery Recycling
Recharging Station must not be used with any
other type of refrigerant.
Refrigerant R134a from domestic and
commercial sources must not be used in motor
vehicle air conditioning systems.

GENERAL INFORMATION
03-30
Remedial actions
If an accident involving R134a should occur, conduct
the following remedial actions:
lIf liquid R134a enters the eye, do not rub it.
Gently run large quantities of eye wash over
affected eye to raise the temperature. If an eye
wash is not available, cool clean water may be
used to flush the eye. After rinsing, cover the
eye with a clean pad and seek immediate
medical attention.
lIf liquid R134a is splashed onto the skin, run
large quantities of water over the affected area
to raise the temperature. Implement the same
action if the skin comes in contact with
discharging cylinders. Wrap the contaminated
body parts in blankets (or similar materials) and
seek immediate medical attention.
lIf the debilitating effects of inhalation of R134a
vapour is suspected, seek fresh air. If the
affected person is unconscious, move them
away from the contaminated area to fresh air
and apply artificial respiration and/or oxygen
and seek immediate medical attention.
Service precautions
Observe the following precautions when handling
components used in the air conditioning system:
lAir conditioning units must not be lifted by their
hoses, pipes or capillary lines.
lHoses and lines must not be subjected to any
twist or stress - the efficiency of the system will
be impaired by kinks or restrictions. Ensure that
hoses are correctly positioned before tightening
couplings, and ensure that all clips and supports
are utilised.
lFlexible hoses should not be positioned close to
the exhaust manifold (less than 100mm) unless
protected by heat shielding.
lCompleted assemblies must be checked for
refrigeration lines touching metal panels. Any
direct contact of components and panels may
transmit noise and so must be eliminated.
lThe appropriate torque wrench must be used
when tightening refrigerant connections to the
stipulated value. An additional spanner must be
used to hold the union to prevent twisting of the
pipe when tightening connections.
lBefore connecting any hose or pipe, ensure that
refrigerant oil is applied to the seat of the new
'O' ring seals, BUT NOT to the threads of the
connection.
lAll protective plugs must remain in place to seal
the component until immediately prior to
connection.
lEnsure components are at room temperature
before uncapping, to prevent condensation of
moisture from the air that enters it.
lComponents must not remain uncapped for
longer than 15 minutes. In the event of a delay,
the caps must be fitted.
lWhen disconnecting, immediately cap all air
conditioning pipes to prevent ingress of dirt and
moisture into the system.
lThe modulator (receiver/drier) contains
desiccant which absorbs moisture. It must be
positively sealed at all times. A modulator that
has been left uncapped must not be used, fit a
new unit.
lThe modulator should be the last component
connected to the system to ensure optimum
dehydration and maximum moisture protection
of the system.
lWhenever the refrigerant system is opened, the
modulator must be renewed immediately before
evacuating and recharging the system.
lUse alcohol and a clean lint-free cloth to clean
dirty connections.
lEnsure that all new parts fitted are marked for
use with R134a.

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

MAINTENANCE
10-28 MAINTENANCE
Steering
Check
1.Check/tighten steering unit and steering rod
ball joint fixings.
2.Check condition of ball joints and dust covers.
3.Check steering rack bellows for any signs of
leakage.
Road Test
There are two purposes for conducting a road test.
Firstly, to ensure the work completed within the
dealership meets the standards required as laid
down by dealership processes. Secondly, for a
skilled technician to assess the general condition of
the vehicle and report any conditions that the
customer should be made aware of.
CAUTION: Two wheel dynamometer tests must
not be carried out. Four wheel dynamometer
tests must be restricted to 3 mph (5 kph).
Engine Start
1.Check for correct operation of starter switch.
Ensure the engine starts in a correct manner.
Leave the engine running.
Starter Inhibitor Switch – (Automatic only)
1.Select 'D' gear lever position.
2.Check that engine will not start.
3.Select 'R' gear lever position and repeat start
check.
4.Check that engine will start in 'P' and 'N'
positions.
Selector Cable – (Automatic only)
1.Check for correct setting of gear selector cable.
Engine Performance and Throttle Operation
1.Start engine and check that it starts easily.
2.Check that 'oil pressure' and 'no charge'
warning lamps extinguish.
3.Check that throttle pedal movement is free and
unrestricted.
4.Check that engine is responsive to throttle
movement.
Clutch and Gear Selection –
(Manual only, normal driving conditions)
1.Check that clutch engages smoothly without
judder, slipping or noise.
2.Check for abnormal transmission noise.
3.Check for smooth quiet gear changes and that
gear selected engages easily.

ENGINE - K SERIES KV6
OVERHAUL 12-3-77
OVERHAUL
Piston assemblies - engine set
$% 12.17.03.01
Disassembly
1.Remove crankshaft.

+ ENGINE - K SERIES KV6,
OVERHAUL, Crankshaft.
2.Remove LRT-12-144 cylinder liner clamps from
cylinder block.
3.Suitably identify each cylinder liner to its fitted
position in cylinder block.
4.With assistance, position cylinder block to
enable each piston and cylinder liner to be
removed.
5.Carefully push each piston assembly and
cylinder liner from cylinder block.
CAUTION: Suitably identify each piston with
its respective cylinder liner.6.Remove piston assemblies from liners, keep
liners in their fitted order.
7.Refit caps onto connecting rods, lightly tighten
dowel bolts.
8.Using a suitable expander, remove and discard
piston rings from each piston.
9.Using a squared off end of an old piston ring,
remove carbon from piston ring grooves.
Inspect
1. Cylinder liner bores: Measure wear and taper
in two axis 65 mm (2.5 in) from top of cylinder
liner bore The cylinder liner grade is marked on
outside diameter of liner.
CAUTION: Cylinder liners with excessively
glazed, worn, scratched or scored bores
must be replaced. DO NOT attempt to hone
or remove glazing from bore. Ensure that if
original liners are to be refitted, reference
marks made during dismantling are not
erased.

ENGINE - K SERIES KV6
12-3-78 OVERHAUL
2.Cylinder liners have their bore/grade and step
height determined at manufacture. The bore/
grade, red, blue (A) or (B), and step heights V
or Z together with the cylinder liner part number
and colour code are marked on the external
diameter of the cylinder liners. If cylinder(s) are
to be replaced, the replacement liner(s) must
have the same step height as the original
liner(s). Both step heights are available in red
(A) and blue (B) grades of cylinder liners.

+ GENERAL DATA, Engine - KV6
Petrol.
3.Check pistons for distortion and cracks.
NOTE: Piston grades A or B are stamped on
the crown of the piston.
4. Piston diameter check: Measure piston
diameter at right angles to gudgeon pin and 8
mm (0.3 in) from bottom of skirt.

+ GENERAL DATA, Engine - KV6
Petrol.
NOTE: Piston and connecting rods are only
supplied as an assembly.
CAUTION: Ensure pistons are retained with
their respective cylinder liners.
5.Position piston in cylinder liner and measure
clearance 20 mm (0.75 in) from bottom of
cylinder liner.

+ GENERAL DATA, Engine - KV6
Petrol.6. Piston ring gap: Position new top and second
compression piston rings 20 mm (0.75 in) from
top of cylinder bore and measure ring gaps.

+ GENERAL DATA, Engine - KV6
Petrol.
CAUTION: Ensure piston rings are kept
square to liner bore. Retain rings with the
piston fitted to the liner in which they were
checked.
7. Piston rings - refit:Using a suitable expander,
fit oil control spring.
8.With 'TOP' or identification markings to top of
piston, use an expander to fit piston rings in
sequence; oil control, 2nd and top
compression.
NOTE: The second compression ring is
stepped.
M12 6838