fuel cap LAND ROVER FREELANDER 2001 Workshop Manual

CONTENTS
CONTENTS 3
TORQUE WRENCH SETTINGS .............................................................. 06-1
Maintenance ................................................................................................................................... 06-1
Engine – Td4................................................................................................................................... 06-2
Engine – K1.8 ................................................................................................................................. 06-4
Engine – KV6 .................................................................................................................................. 06-6
Emission Control ............................................................................................................................. 06-8
Engine Management System – EDC .............................................................................................. 06-9
Engine Management System – MEMS ........................................................................................... 06-10
Engine Management System – Siemens ........................................................................................ 06-11
Fuel Delivery System – Diesel ........................................................................................................ 06-12
Fuel delivery system – Petrol .......................................................................................................... 06-13
Cooling System – Td4..................................................................................................................... 06-14
Cooling System – K1.8 ................................................................................................................... 06-14
Cooling System – KV6 .................................................................................................................... 06-14
Manifolds and Exhaust System – Td4 ............................................................................................ 06-15
Manifolds and Exhaust Systems – K1.8 ......................................................................................... 06-16
Manifolds and Exhaust Systems – KV6 .......................................................................................... 06-17
Clutch .............................................................................................................................................. 06-18
Manual Gearbox – PG1 .................................................................................................................. 06-19
Manual Gearbox – Getrag .............................................................................................................. 06-20
Intermediate Reduction Drive ......................................................................................................... 06-21
Automatic Gearbox – Jatco ............................................................................................................. 06-22
Driveshafts ...................................................................................................................................... 06-23
Rear Axles and Final Drive ............................................................................................................. 06-24
Steering........................................................................................................................................... 06-25
Front Suspension and Subframe .................................................................................................... 06-26
Rear Suspension and Subframe ..................................................................................................... 06-27
Brakes ............................................................................................................................................. 06-28
Supplementary Restraint Systems .................................................................................................. 06-29
Body ................................................................................................................................................ 06-30
Heating and Ventilation ................................................................................................................... 06-32
Air Conditioning............................................................................................................................... 06-33
Wipers and Washers ....................................................................................................................... 06-34
Electrical ......................................................................................................................................... 06-35
LIFTING AND TOWING ........................................................................... 08-1
Jacking ............................................................................................................................................ 08-1
Towing ............................................................................................................................................ 08-2
Emergency starting ......................................................................................................................... 08-4
CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS ...................... 09-1
Capacities ....................................................................................................................................... 09-1
Fluids .............................................................................................................................................. 09-2
Lubrication ...................................................................................................................................... 09-3
Sealants .......................................................................................................................................... 09-4

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
03-7
General fitting instructions
Precautions against damage
To avoid damage to the vehicle when carrying out
repairs, always adhere to the following:
lAlways fit wing and seat covers before
commencing work. Avoid spilling brake fluid or
battery acid on paintwork; immediately wash off
with water if this occurs.
lDisconnect the battery earth lead before starting
work, see ELECTRICAL PRECAUTIONS.
lAlways use the recommended service tool or a
satisfactory equivalent where specified.
lProtect exposed bearing surfaces, sealing
surfaces and screw threads from damage.
Component removal
Whenever possible, clean components and
surrounding area before removal.
lBlank off openings exposed by component
removal.
lImmediately seal fuel, oil or hydraulic lines when
apertures are exposed; use plastic caps or
plugs to prevent loss of fluid and ingress of dirt.
lClose open ends of oilways exposed by
component removal with tapered hardwood
plugs or conspicuous plastic plugs.
lImmediately a component is removed, place it in
a suitable container; use a separate container
for each component and its associated parts.
lClean bench and provide marking materials,
labels, containers and locking wire before
dismantling a component.
Dismantling
Observe scrupulous cleanliness when dismantling
components, particularly when brake, fuel or
hydraulic system parts are being worked on. A
particle of dirt or a cloth fragment could cause a
serious malfunction if trapped in these systems.Use the following procedures:
lBlow out all tapped holes, crevices, oilways and
fluid passages with an air line. Ensure that any
O-rings used for sealing are correctly replaced
or renewed if disturbed during the process.
lUse marking ink to identify mating parts and
ensure correct reassembly. Do not use a centre
punch or scriber to mark parts, they could
initiate cracks or distortion in marked
components.
lWire together mating parts where necessary to
prevent accidental interchange (e.g. roller
bearing components).
lWire labels on to all parts which are to be
renewed, and to parts requiring further
inspection before being passed for reassembly;
place these parts in separate containers from
those containing parts for rebuild.
lDo not discard a part due for renewal until after
comparing it with a new part to ensure that its
correct replacement has been obtained.
Cleaning components
Always use the recommended cleaning agent or
equivalent. Ensure that adequate ventilation is
provided when volatile degreasing agents are being
used. Do not use degreasing equipment for
components containing items which could be
damaged by the use of this process.
When washing under bonnet, never direct water onto
ECM, as water ingress may occur resulting in
damage to electrical components inside.
General Inspection
All components should be inspected for wear or
damage before being reassembled.
lNever inspect a component for wear or
dimensional check unless it is absolutely clean;
a slight smear of grease can conceal an
incipient failure.
lWhen a component is to be checked
dimensionally against recommended values,
use the appropriate measuring equipment
(surface plates, micrometers, dial gauges etc.).
Ensure the measuring equipment is calibrated
and in good serviceable condition.
lReject a component if its dimensions are
outside the specified tolerances, or if it appears
to be damaged.
lA part may be refitted if its critical dimension is
exactly to its tolerance limit and it appears to be
in satisfactory condition.
lUse 'Plastigauge' 12 Type PG-1 for checking
bearing surface clearances.

GENERAL INFORMATION
03-18
Fuel handling precautions
Fuel vapour is highly inflammable and in confined
spaces is also explosive and toxic. The vapour is
heavier than air and will always fall to the lowest
level. The vapour can easily be distributed
throughout a workshop by air currents;
consequently, even a small spillage of fuel is
potentially very dangerous.
The following information provides basic precautions
which must be observed if petrol (gasoline) is to be
handled safely. It also outlines other areas of risk
which must not be ignored. This information is issued
for basic guidance only, if in doubt consult your local
Fire Officer.
General
Always have a fire extinguisher containing FOAM,
CO
2, GAS or POWDER close at hand when handling
or draining fuel or when dismantling fuel systems.
Fire extinguishers should also be located in areas
where fuel containers are stored.
Always disconnect the vehicle battery before
carrying out dismantling or draining work on a fuel
system.
Whenever fuel is being handled, drained or stored, or
when fuel systems are being dismantled, all forms of
ignition must be extinguished or removed; any
leadlamps must be flameproof and kept clear of
spillage.
WARNING: No one should be permitted to repair
components associated with fuel without first
having specialist training.
WARNING: Do not remove fuel system
components while the vehicle is over a pit.Fuel tank draining
Fuel tank draining should be carried out in
accordance with the procedure outlined in the FUEL
DELIVERY section of this manual and observing the
following precautions:
WARNING: Fuel must not be extracted or drained
from any vehicle while it is over a pit. Extraction
or draining of fuel must be carried out in a well
ventilated area.
The capacity of containers must be more than
adequate for the amount of fuel to be extracted or
drained. The container should be clearly marked
with its contents and placed in a safe storage
area which meets the requirements of local
authority regulations.
WARNING: When fuel has been drained from a
fuel tank the precautions governing naked lights
and ignition sources should be maintained.
Fuel tank removal
When the fuel line is secured to the fuel tank outlet by
a spring steel clip, the clip must be released before
the fuel line is disconnected or the fuel tank is
removed. This procedure will avoid the possibility of
residual petrol fumes in the fuel tank being ignited
when the clip is released.
As an added precaution, fuel tanks should have a
'FUEL VAPOUR' warning label attached to them as
soon as they are removed from the vehicle.
Fuel tank repairs
No attempt should be made to repair a plastic fuel
tank. If the structure of the tank is damaged, a new
tank must be fitted.
Body repairs
Plastic fuel pipes are particularly susceptible to heat,
even at relatively low temperature, and can be
melted by heat conducted from some distance away.
When body repairs involve the use of heat, all fuel
pipes which run in the vicinity of the repair area must
be removed, and the tank outlet plugged.

GENERAL DATA
04-1
GENERAL DATA
Engine - Td4 Diesel
General
Type 2.0 litre in-line direct injection diesel, 16-valve, DOHC, turbocharged
and intercooled
Cylinder arrangement 4 in-line, transverse, No.1 cylinder at front of engine
Bore 84.00 mm (3.307 in.)
Stroke 88.00 mm (3.465 in.)
Capacity 1951 cm
3 (119.05 in3)
Firing order 1-3-4-2
Compression ratio 18:1 ± 0.5:1
Direction of rotation Clockwise, viewed from the front of the engine
Maximum power:
⇒ Up to 03 Model Year - Manual and automatic
gearbox
⇒ 03 Model Year onwards - Manual gearbox
⇒ 03 Model Year onwards - Automatic gearbox82 kW (112 bhp) @ 4000 rev/min.
82 kW (112 bhp) @ 4000 rev/min
80 kW (107 bhp) @ 4000 rev/min
Maximum torque 260 Nm (192 lbf.ft) @ 1750 rev/min.
Maximum governed speed 4800 rev/min.
Maximum overrun speed 5250 rev/min
Idle speed 780 ± 30 rev/min
Dimensions:
⇒ Length
⇒ Width
⇒ Height482 mm (19.0 in)
634 mm (25.0 in)
697 mm (27.4 in)
Glow plugs: 4 off, one per cylinder arranged centrally on inlet side between inlet
valves
Turbocharger Garrett GT2
Fuel injection system: Common rail, direct injection fed by Bosch high pressure delivery
pump
Injection timing Controlled by ECM
Emissions standard ECD3
Valve timing
Inlet valves:
⇒ Opens
⇒ Closes8° BTDC
28° ABDC
Exhaust valves:
⇒ Opens
⇒ Closes38° BBDC
4° ATDC

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

TORQUE WRENCH SETTINGS
06-2
Engine – Td4
TORQUE DESCRIPTION METRIC IMPERIAL
Acoustic cover to engine 8 Nm 6 lbf.ft
Ancillary drive belt jockey pulley Allen bolt
*24 Nm 18 lbf.ft
Ancillary drive belt tensioner arm nut 10 Nm 7.5 lbf.ft
Big end bearing cap bolts:
⇒ Stage 15 Nm 3.5 lbf.ft
⇒ Stage 225 Nm 18 lbf.ft
⇒ Stage 3+70°+70°
Camshaft bearing cap bolts
† 10 Nm 7.5 lbf.ft
Camshaft cover bolts
† 10 Nm 7.5 lbf.ft
Camshaft sprocket retaining screw:
⇒ Stage 120 Nm 15 lbf.ft
⇒ Stage 2+35°+35°
Chain lubrication jet bolt 10 Nm 7.5 lbf.ft
Coolant rail to exhaust manifold bolts 20 Nm 15 lbf.ft
Coolant rail to exhaust manifold bolts 8 Nm 6 lbf.ft
Crankshaft pulley:
⇒ Stage 1100 Nm 74 lbf.ft
⇒ Stage 2+60 °+60 °
⇒ Stage 3+60 °+60 °
⇒ Stage 4+30 °+30 °
Crankshaft rear oil seal housing:
⇒ M6 bolts10 Nm 7.5 lbf.ft
⇒ M8 bolts22 Nm 16 lbf.ft
Cylinder block reinforcing plate 22 Nm 16 lbf.ft
Cylinder head bolts: (Stages 1 to 5 relate to bolts 1 to 11. Stage 6 is for bolt 12 only.)
⇒ Stage 1
†80 Nm 59 lbf.ft
⇒ Stage 2 - loosen all bolts
†-1/2 turn -1/2 turn
⇒ Stage 3
†50 Nm 37 lbf.ft
⇒ Stage 4
†+90°+90°
⇒ Stage 5
†+90°+90°
⇒ Stage 6 – tighten 41 mm bolt in position 12 110 Nm 81 lbf.ft
Cylinder head to timing cover Allen screws 15 Nm 11 lbf.ft
Dipstick tube to oil filter housing bolt 10 Nm 7.5 lbf.ft
Drive plate to crankshaft bolts
† 115 Nm 85 lbf.ft
EGR cooler to cylinder head and lifting bracket bolts 25 Nm 18 lbf.ft
Engine breather pipe to air cleaner housing bolt 10 Nm 7.5 lbf.ft
Engine lifting eye bolts 20 Nm 15 lbf.ft
Engine mounting bracket assembly to engine bolts 100 Nm 74 lbf.ft
Engine mounting bracket to hydramount nut 85 Nm 63 lbf.ft
Engine lower steady bracket bolts:
⇒ M1045 Nm 33 lbf.ft
⇒ M1250 Nm 37 lbf.ft
Engine steady mounting bolt 100 Nm 74 lbf.ft
Exhaust manifold to cylinder head nuts 24 Nm 18 lbf.ft
Flywheel to crankshaft bolts
† 115 Nm 85 lbf.ft
Fuel pipe bracket to oil filter housing bolt 10 Nm 7.5 lbf.ft
Fuel pipe union nuts 30 Nm 22 lbf.ft
Fuel pump drive chain lower guide Allen bolt 24 Nm 18 lbf.ft

TORQUE WRENCH SETTINGS
06-3
† Tighten in sequence
* Fit new bolt
Fuel pump sprocket retaining nut 65 Nm 48 lbf.ft
Fuel rail Allen screws 24 Nm 18 lbf.ft
Fuel rail to coolant rail bolts 10 Nm 7.5 lbf.ft
Fuel rail to support bracket bolts 10 Nm 7.5 lbf.ft
Glow plugs18 Nm 13 lbf.ft
Heatshield to coolant rail Allen screws 8 Nm 6 lbf.ft
Hose adaptor to cylinder head bolts 8 Nm 6 lbf.ft
LH engine mounting to gearbox bracket through bolt 100 Nm 74 lbf.ft
LH engine mounting to body 45 Nm 33 lbf.ft
Lower coolant rail support bracket bolts 15 Nm 11 lbf.ft
Main bearing cap bolts:
⇒ 1st. Stage
† 20 Nm 15 lbf.ft
⇒ 2nd Stage
† +70°+70°
Oil cooler to oil filter housing bolts 22 Nm 16 lbf.ft
Oil feed guide rail bolts 10 Nm 7.5 lbf.ft
Oil filter cap25 Nm 18 lbf.ft
Oil filter housing bolts 25 Nm 18 lbf.ft
Oil pick-up strainer to oil pump bolts 10 Nm 7.5 lbf.ft
Oil pressure switch 38 Nm 28 lbf.ft
Oil pump drive gear to oil pump drive shaft Torx bolt 25 Nm 18 lbf.ft
Oil pump to cylinder block 25 Nm 18 lbf.ft
PAS pipe clip to engine lifting eye bolt 10 Nm 7.5 lbf.ft
Sump: †
⇒ M6 bolts10 Nm 7.5 lbf.ft
⇒ M8 bolts28 Nm 21 lbf.ft
Sump drain plug28 Nm 21 lbf.ft
Sump plate bolts10 Nm 7.5 lbf.ft
Timing chain support guides 20 Nm 15 lbf.ft
Timing chain tensioner access plug 30 Nm 22 lbf.ft
Timing chain tensioner bolt 10 Nm 7.5 lbf.ft
Timing cover bolts
† 15 Nm 11 lbf.ft
Turbocharger to exhaust manifold bolts 45 Nm 33 lbf.ft
Turbocharger outlet pipe fixing bolts:
⇒ 6mm10 Nm 7.5 lbf.ft
⇒ 8mm25 Nm 18 lbf.ft
Vacuum pump bolts 22 Nm 16 lbf.ft

LIFTING AND TOWING
08-1
LIFTING AND TOWING
Jacking
The following instructions must be carried out before
raising the vehicle off the ground:
lUse a solid level surface.
lApply parking brake.
lSelect 1st. gear in main gearbox and ensure
HDC is not selected.
CAUTION: To avoid damage to under body
components of the vehicle, adhere to the
following jacking procedures:
DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS:
lBumpers
lBrake or Fuel lines
lExhaust pipe
lSuspension components
lSteering rack and linkages
lFuel tank
lEngine sump
lGearbox
lIRD unit
Jack or support vehicle only on approved jacking
points as detailed in the following illustration:
Front (hydraulic jack) and side (vehicle jack) jacking
pointsSafety stand positions under longitudinal members
Rear (hydraulic jack) and side (vehicle jack) jacking
points
Vehicle jack
The jack provided with the vehicle is only intended to
be used in an emergency, for changing a tyre. Do
NOT use the jack for any other purpose. Refer to the
Owner's Handbook for vehicle jack location points
and procedure. Never work under a vehicle only
supported by the vehicle jack.
Hydraulic jack
A hydraulic jack with a minimum 1500 kg (3,300 lbs)
load capacity must be used.
WARNING: Do not work on or under a vehicle
supported only by a jack. Always support the
vehicle on safety stands.