coil LAND ROVER FREELANDER 2001 Workshop Manual

CONTENTS
6CONTENTS
EMISSION CONTROL ............................................................................. 17-1-1
ADJUSTMENTS
Evaporative loss control system (EVAPS) - leak test - NAS........................................................... 17-1-1
REPAIRS
Valve - depression limiter - Td4 ..................................................................................................... 17-1-3
Solenoid - canister purge - KV6 ...................................................................................................... 17-1-4
Charcoal canister - petrol - Non NAS ............................................................................................. 17-1-4
Charcoal canister - NAS ................................................................................................................. 17-1-5
Valve - canister purge - K1.8 .......................................................................................................... 17-1-6
Valve - EGR - Td4 .......................................................................................................................... 17-1-7
Solenoid/modulator valve - EGR - Td4 ........................................................................................... 17-1-8
Thermal valve - exhaust gas recirculation (EGR) -
Td4 Automatic transmission (hot climates) - from 03 MY ............................................................... 17-1-9
Cooler - EGR - Td4 ......................................................................................................................... 17-1-9
Module - tank leakage diagnostic (DMTL) ...................................................................................... 17-1-11
Filter - fuel leak detection pump - KV6 - NAS ................................................................................ 17-1-12
Catalytic converter - RH - KV6 - NAS ............................................................................................ 17-1-12
ENGINE MANAGEMENT SYSTEM - SIEMENS....................................... 18-3-1
REPAIRS
Spark plugs - up to 03MY ............................................................................................................... 18-3-1
Spark plugs - from 03MY ................................................................................................................ 18-3-2
Coil - each - LH bank - up to 03MY ................................................................................................ 18-3-3
Coil - each - LH bank - from 03MY ................................................................................................. 18-3-3
Coil - each - RH bank - up to 03MY ................................................................................................ 18-3-4
Coil - each - RH bank - from 03MY................................................................................................. 18-3-4
Engine control module (ECM) - Non NAS ..................................................................................... 18-3-5
Engine control module (ECM) - fuel - NAS .................................................................................... 18-3-6
Idle Air Control Valve (IACV) ......................................................................................................... 18-3-7
Sensor - intake air temperature (IAT) - NAS .................................................................................. 18-3-8
Sensor - engine coolant temperature (ECT) .................................................................................. 18-3-8
Sensor - crankshaft position (CKP) ............................................................................................... 18-3-9
Sensor - throttle position (TP) ......................................................................................................... 18-3-10
Sensor - thermostat monitoring (TM) - KV6 - NAS ........................................................................ 18-3-11
Sensor - camshaft position (CMP) ................................................................................................. 18-3-12
Sensor - knock (KS) ....................................................................................................................... 18-3-13
Switch - throttle pedal - Non NAS ................................................................................................... 18-3-13
Sensor - combined - manifold absolute pressure/Intake air temperature (MAP/IAT) ..................... 18-3-14
Sensor - throttle position (TP) - NAS - up to 03MY......................................................................... 18-3-15
Sensor - throttle position (TP) - NAS - from 03MY ......................................................................... 18-3-16

CONTENTS
20 CONTENTS
LIGHTING.................................................................................................. 86-2-1
ADJUSTMENTS
Headlamps - pair - align beam - up to 04MY .................................................................................. 86-2-1
Headlamps - pair - align beam - from 04MY ................................................................................... 86-2-1
REPAIRS
Headlamp assembly - up to 04MY.................................................................................................. 86-2-3
Headlamp assembly - from 04MY .................................................................................................. 86-2-4
Lamp assembly - flasher side repeater - front ................................................................................ 86-2-5
Lamp assembly - tail ....................................................................................................................... 86-2-5
Lamp assembly - number plate ...................................................................................................... 86-2-6
Lamp assembly - fog/driving - from 04MY ...................................................................................... 86-2-6
Lamp assembly - rear ..................................................................................................................... 86-2-7
Lamp assembly - centre high mounted stop (CHMSL) ................................................................... 86-2-7
Lamp assembly - glove compartment ............................................................................................. 86-2-8
Lamp assembly - load space .......................................................................................................... 86-2-8
Switch - headlamp levelling ............................................................................................................ 86-2-9
Switch - glove compartment ........................................................................................................... 86-2-9
Switch - hazard warning ................................................................................................................. 86-2-10
Switch - combined direction indicator/headlight/horn ..................................................................... 86-2-10
Switch - rear fog lamp ..................................................................................................................... 86-2-11
CONTROL UNITS ..................................................................................... 86-3-1
REPAIRS
Control unit - window lift ................................................................................................................. 86-3-1
Relay - power folding mirrors - from 02MY ..................................................................................... 86-3-1
Central Control Unit (CCU) ............................................................................................................. 86-3-2
Control Unit - power fold mirrors - up to 02MY ............................................................................... 86-3-3
SECURITY................................................................................................. 86-4-1
REPAIRS
Solenoid/motor - taildoor................................................................................................................. 86-4-1
Switch/push - horn .......................................................................................................................... 86-4-2
Horn ................................................................................................................................................ 86-4-2
Immobilisation - electronic control unit (ECU) - ............................................................................. 86-4-3
Sensor - volumetric - alarm system - 3 door ................................................................................... 86-4-3
Module (ECU) - volumetric - alarm system - 5 door - without sunroof ........................................... 86-4-5
Module (ECU) - volumetric - alarm system - 5 door - with sunroof ................................................ 86-4-7
Receiver - alarm system ................................................................................................................. 86-4-10
Coil - passive immobilisation - alarm system .................................................................................. 86-4-10

GENERAL INFORMATION
03-19
Electrical precautions
General
The following guidelines are intended to ensure the
safety of the operator and ensure the prevention of
damage to the electrical and electronic components
fitted to the vehicle. Where necessary, specific
precautions are detailed in the individual procedures
of this manual.
Equipment
Prior to commencing any test procedure on the
vehicle, ensure that the relevant test equipment is
working correctly and any harness or connectors are
in good condition. It is particularly important to check
the condition of the lead and plugs of mains operated
equipment.
Polarity
Never reverse connect the vehicle battery and
always ensure the correct polarity when connecting
test equipment.
High Voltage Circuits
Whenever disconnecting live ht circuits, always use
insulated pliers and never allow the open end of the
ht lead to contact other components, particularly
ECU's.
Exercise caution when measuring the voltage on the
coil terminals while the engine is running, high
voltage spikes can occur on these terminals.
Connectors and harnesses
The engine compartment of a vehicle is a particularly
hostile environment for electrical components and
connectors:
lAlways ensure electrically related items are dry
and oil free before disconnecting and
connecting test equipment.
lEnsure disconnected multiplugs and sensors
are protected from being contaminated with oil,
coolant or other solutions. Contamination could
impair performance or result in catastrophic
failure.
lNever force connectors apart using tools to
prise apart or by pulling on the wiring harness.
lAlways ensure locking tabs are disengaged
before disconnection, and match orientation to
enable correct reconnection.
lEnsure that any protection (covers, insulation
etc.) is replaced if disturbed.Having confirmed a component to be faulty:
lSwitch off the ignition and disconnect the
battery.
lRemove the component and support the
disconnected harness.
lWhen replacing the component, keep oily hands
away from electrical connection areas and push
connectors home until any locking tabs fully
engage.
Battery disconnection
Before disconnecting the battery, disable the alarm
system and switch off all electrical equipment. If the
radio is to be serviced, ensure the security code has
been deactivated.
CAUTION: To prevent damage to electrical
components, always disconnect the battery
when working on the vehicle's electrical system.
The ground lead must be disconnected first and
reconnected last.
CAUTION: Always ensure that battery leads are
routed correctly and are not close to any
potential chafing points.
Battery charging
Only recharge the battery with it removed from the
vehicle. Always ensure any battery charging area is
well ventilated and that every precaution is taken to
avoid naked flames and sparks.
Ignition system safety precautions
The vehicle's ignition system produces high voltages
and the following precautions should be observed
before carrying out any work on the system:
WARNING: Before commencing work on an
ignition system, ensure all high tension
terminals, adapters and diagnostic equipment
are adequately insulated and shielded to prevent
accidental personal contacts and minimise the
risk of shock. Wearers of surgically implanted
pacemaker devices should not be in close
proximity of ignition circuits or diagnostic
equipment.

GENERAL DATA
04-5
Valves
Stem diameter:
⇒ Inlet 5.97 ± 0.01 mm (0.235 ± 0.0004 in.)
⇒ Exhaust 5.97 ± 0.01 mm (0.235 ± 0.0004 in.)
Valve stem to guide clearance 0.025 - 0.054 mm (0.0010 - 0.0021 in.)
Valve head stand down:
⇒ Inlet 0.73 ± 0.1 mm (0.029 ± 0.004 in.)
⇒ Exhaust 0.56 ± 0.1 mm (0.022 ± 0.004 in.)
Head diameter 25.9 ± 0.1 mm (1.02 ± 0.004 in.)
Valve seat angle: 45°
Valve seat width:
⇒ Inlet 1.20 ± 0.15 mm (0.047 ± 0.006 in)
⇒ Exhaust 1.45 ± 0.15 mm (0.057 ± 0.006 in)
Valve springs
Type Parallel, single coil
Free length 47.5 mm (1.87 in.)
Fitted length 32 mm (1.26 in.)

GENERAL DATA
04-6
Engine - K1.8 Petrol
General
Type 1.8 litre petrol, 16-valve DOHC
Cylinder arrangement 4 in-line, transverse, No.1 cylinder at front of engine
Bore 80.00 mm (3.150 in.)
Stroke 89.30 mm (3.516 in.)
Capacity 1796 cm
3 (109.59 in3)
Firing order 1-3-4-2
Compression ratio 10.5 :1 ± 0.5 :1
Direction of rotation Clockwise viewed from the front of the engine
Maximum power 88 kW (118 bhp) @ 5500 rev/min.
Maximum torque 165 Nm (223.7 lbf.ft) @ 2750 rev/min.
Idle speed 775 ± 50 rev/min.
Maximum intermittent engine speed 6750 rev/min.
Weight (fully dressed, wet) 108 kg (238 lb)
Dimensions:
⇒ Length (nominal) 654 mm (25.75 in.)
⇒ Width (nominal) 600 mm (23.62 in.)
⇒ Height (nominal) 615 mm (24.21 in.)
Spark plugs:
⇒ Type NLP 100290
⇒ Gap 1.0 mm ± 0.05 mm (0.039 in. ± 0.002 in.)
Ignition coils:
⇒ Make Nippon Denso - NEC 100730
⇒ Type 2 x twin output coils, plug top mounted; cylinders 1 & 4 and 2 & 3
⇒ Primary resistance (typical) 0.7 Ω
⇒ Secondary resistance (typical) 10 Ω
Fuel injection system:
Type Returnless fuel rail, multi-point fuel injection, electronically controlled
from ECM
Controller MEMS 3 breakerless, electronic, fully mapped engine management
system
Injectors:
⇒ Operating pressure 3.5 bar (50.8 lbf.in
2)
⇒ Fuel flow rate 117 g/min. @ 3.0 bar (4.13 fl.oz/min. @ 43.5 lbf. in
2)
Valve operation Self-adjusting, lightweight hydraulic tappets operated directly by
camshafts
Emissions standard ECD3
Cylinder block:
Material Aluminium alloy
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 - 3.1501 in.)
⇒ BLUE grade B 80.016 - 80.030 mm (3.1502 - 3.1508 in.)

GENERAL DATA
04-11
Engine - KV6 Petrol
General
Type:
⇒ Up to 03 Model Year
⇒ From 03 Model Year2.5 litre V6, 24 valve, air assisted direct fuel injection petrol, water
cooled, transverse mounted
2.5 litre V6, 24 valve, direct fuel injection petrol, water cooled,
transverse mounted
Cylinder arrangement: 90° V6, numbered from the front of the engine
⇒ Left bank Cylinders 1, 3 and 5
⇒ Right bank Cylinders 2, 4 and 6
Bore (nominal) 80 mm (3.15 in.)
Stroke 82.8 mm (3.26 in.)
Capacity 2497 cm
3 (152.37 in3)
Firing order 1-6-5-4-3-2
Compression ratio 10.5 : 1 ± 0.5 : 1
Direction of rotation Clockwise viewed from front of engine
Maximum power 130 kW (177 bhp) @ 6500 rev/min.
Maximum torque 240.0 Nm (177 lbf.ft) @ 4000 rev/min.
Maximum engine speed:
⇒ Continuous 6500 rev/min.
⇒ Intermittent 6750 rev/min.
Idle speed 750 rev/min. ± 50 rev/min.
Weight (fully dressed, wet) 154 kg (340 lb)
Dimensions (dressed):
⇒ Length (nominal) 770 mm (30.3 in.)
⇒ Width (nominal) 750 mm (29.5 in.)
⇒ Height (nominal) 750 mm (29.5 in.)
Valve operation Self-adjusting lightweight hydraulic tappets operated directly by the
camshafts
Fuel injection system:
⇒ Make - Up to 03 Model Year
⇒ Make - From 03 Model YearSiemens engine management system
Siemens engine management system
⇒ Type - Up to 03 Model Year
⇒ Type - From 03 Model YearMulti-point, air assisted fuel injection controlled by ECM, electro-
mechanical injectors with twin sprays targeted on to back of inlet
valves
Multi-point fuel injection controlled by ECM, electro-mechanical
injectors with quadruple sprays targeted on to back of inlet valves
Inlet manifold Variable geometry
Spark plugs
⇒ Type
⇒ Plug gapNLP 100290
1.0 mm ± 0.05 mm (0.039 in. ± 0.002 in.)
Coils:
⇒ Make - Up to 03 Model Year
⇒ Make - From 03 Model Year
⇒ Type - Up to 03 Model Year
⇒ Type - From 03 Model YearBREMR
Champion BAE 403H
6 x coils (3 x plug top, 3 x remote mounted)
6 x coils (6 x plug top)
Emissions standard ECD3

GENERAL DATA
04-28
Front Suspension
Type Independent, MacPherson struts with coil springs, lower "L" shaped
arms and anti-roll bar
Nominal height to wheel arch from hub centre* 453 mm (17.83 in)
Road spring identification (colour code):
Td4 with manual gearbox
⇒ Colour code YELLOW / BLUE
⇒ Total coils 6
⇒ Active coils 5
⇒ Wire diameter 14.87 mm (0.585 in)
⇒ Free length 367 mm (14.45 in)
Td4 with automatic gearbox, non air conditioning
⇒ Colour code YELLOW / WHITE
⇒ Total coils 6
⇒ Active coils 5
⇒ Wire diameter 14.87 mm (0.585 in)
⇒ Free length 367 mm (14.445 in)
Td4 with automatic gearbox and air conditioning
⇒ Colour code YELLOW / BROWN
⇒ Total coils 6
⇒ Active coils 5
⇒ Wire diameter 14.866 mm (0.5853 in)
⇒ Free length 375 mm (14.76 in)
K1.8 without air conditioning
⇒ Colour code YELLOW / PINK
⇒ Total coils 5.5
⇒ Active coils 4.5
⇒ Wire diameter 14.03 mm (0.552 in)
⇒ Free length 359 mm (14.13 in)
K1.8 with air conditioning
⇒ Colour code YELLOW / GREY
⇒ Total coils 5.5
⇒ Active coils 4.5
⇒ Wire diameter 14.03 mm (0.552 in)
⇒ Free length 359 mm (14.13 in)
KV6 without air conditioning
⇒ Colour code YELLOW / BLUE
⇒ Total coils 6
⇒ Active coils 5
⇒ Wire diameter 14.87 mm (0.585 in)
⇒ Free length 367 mm (14.45 in)
KV6 with air conditioning
⇒ Colour code YELLOW / WHITE
⇒ Total coils 6
⇒ Active coils 5
⇒ Wire diameter 14.87 mm (0.585 in)
⇒ Free length 371 mm (14.61 in)

GENERAL DATA
04-29
From 04MY: Models with Sports Suspension .
⇒ Colour code GREY / ORANGE
⇒ Total coils 5.5
⇒ Active coils 5.5
⇒ Wire diameter 15.5
⇒ Free length 308.5
Anti-roll bar diameter 20.5 mm (0.81 in)
* At unladen weight

GENERAL DATA
04-30
Rear Suspension
* At unladen weight
Type Independent, MacPherson struts with coil springs and lower
"trapezoidal links"
All models, except those with Sports
Suspension:Nominal height to wheel arch from hub
centre*463 mm (18.228 in) ± 10 mm (0.39)
Models with Sports Suspension only:Nominal height
to wheel arch from hub centre*433 mm (17.047 in)
Road spring identification:
All models except Sports Suspension
⇒ Colour code WHITE / GREEN
Total coils 6.42
Active coils 4.7
Wire diameter 13.825 mm (0.5443 in)
Free length 349.86 (13.774 in)
Models with Sports Suspension, (fitted from 04MY)
⇒ Colour code ORANGE / ORANGE
⇒ Total coils 6.8
⇒ Active coils 5.6
⇒ Wire diameter 13.97
⇒ Free length 311

TORQUE WRENCH SETTINGS
06-4
Engine – K1.8
TORQUE DESCRIPTION METRIC IMPERIAL
Big end bearing cap dowel bolts:
⇒ Stage 120 Nm 15 lbf.ft
⇒ Stage 2+45°+45°
Bearing ladder to cylinder block bolts:
⇒ Stage 1
†++5 Nm 3.5 lbf.ft
⇒ Stage 2
† ++30 Nm 22 lbf.ft
Camshaft carrier to cylinder head bolts
†++10 Nm 7.5 lbf.ft
Camshaft cover to carrier bolts
†8 Nm 6 lbf.ft
Camshaft gear bolt 65 Nm 48 lbf.ft
Camshaft rear oil seal cover plate bolts:
⇒ Exhaust25 Nm 18 lbf.ft
⇒ Inlet6 Nm 4.5 lbf.ft
Camshaft sensor bolt 8 Nm 6 lbf.ft
Camshaft timing belt lower front cover bolts 9 Nm 7 lbf.ft
Camshaft drive belt upper front cover bolts 5 Nm 3.5 lbf.ft
Camshaft timing belt rear cover bolts 9 Nm 7 lbf.ft
Camshaft timing belt tensioner bolt
* 25 Nm 18 lbf.ft
Camshaft upper cover to rear cover bolts 5 Nm 3.5 lbf.ft
Coolant outlet elbow to cylinder head bolts 9 Nm 7 lbf.ft
Crankshaft pulley bolt 205 Nm 151 lbf.ft
Cylinder head bolts
⇒ Stage 1
†20 Nm 15 lbf.ft
⇒ Stage 2
†+180 °+180 °
⇒ Stage 3
†+180 °+180 °
Dipstick tube to cylinder block 10 Nm 7.5 lbf.ft
Dipstick tube bracket and thermostat housing to cylinder block bolt 10 Nm 7.5 lbf.ft
Engine earth lead to body nut 9 Nm 7 lbf.ft
Engine harness to oil pump housing bolts 10 Nm 7.5 lbf.ft
Engine LH gearbox mounting bracket through bolt 80 Nm 59 lbf.ft
Engine LH mounting bracket to body bolts 45 Nm 33 lbf.ft
Engine lower steady to sump mounting bracket bolt 80 Nm 59 lbf.ft
Engine lower steady bracket to sump bolts 100 Nm 74 lbf.ft
Engine lower steady to subframe bolt 80 Nm 59 lbf.ft
Engine steady to LH mounting bolt 25 Nm 18 lbf.ft
Engine steady (lower) to rear beam bolt 80 Nm 59 lbf.ft
Engine steady (lower) to sump mounting bracket bolt 80 Nm 59 lbf.ft
Engine steady (upper RH) to body bolt 80 Nm 59 lbf.ft
Engine steady (upper RH) to top arm bolt 80 Nm 59 lbf.ft
Engine to gearbox top and front cover plate bolts and nuts 80 Nm 59 lbf.ft
Flywheel to crankshaft bolts
†*80 Nm 59 lbf.ft
Front cover plate to gearbox M6 bolt 9 Nm 7 lbf.ft
Ignition coils to camshaft cover bolts 8 Nm 6 lbf.ft
Oil pick-up strainer bolt 12 Nm 9 lbf.ft
Oil pick-up strainer support bracket to oil rail bolt 12 Nm 9 lbf.ft
Oil pressure switch
+17 Nm 12.5 lbf.ft
Oil pressure relief valve plug
+25 Nm 18 lbf.ft
Oil pump to cylinder block bolts
†*10 Nm 7.5 lbf.ft
Oil rail to bearing ladder nuts
++9 Nm 7 lbf.ft