fuel cap release LAND ROVER FREELANDER 2001 Workshop Manual

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.

FUEL DELIVERY SYSTEM - PETROL
ADJUSTMENTS 19-2-3
Fuel system - depressurise - KV6 - NAS
$% 19.50.02
Check
1.Remove acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
2. Up to 03MY: Remove nut and bolt securing coil
and position coil aside.
3.Remove schraeder valve cap.
4.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.5.Connect adapter LRT-19-006 to schraeder
valve.
6.Position opposite end of adapter LRT-19-006
into container, turn tap to release pressure.
7.Remove adapter LRT-19-006 from schraeder
valve.
8.Fit cap to schraeder valve.
9. Up to 03MY: Fit and tighten nut and bolt
securing coil.
10.Fit acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.

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

FUEL DELIVERY SYSTEM - PETROL
REPAIRS 19-2-39
Injectors - set - K1.8
$% 19.60.12
Remove
1.Disconnect battery earth lead.
2.Release clip and disconnect vacuum pipe from
fuel pressure regulator.
3.Remove engine oil dipstick.
4.Position absorbent cloth beneath fuel rail.
5.Release fuel feed hose from fuel rail.
CAUTION: Always fit plugs to open
connections to prevent contamination.6.Remove 2 bolts securing fuel rail to inlet
manifold.
7.Release fuel rail and injectors from inlet
manifold.
8.Release and remove injector spacer.
9.Disconnect multiplug from injectors.
10.Remove the fuel rail complete with injectors.
11.Release spring clips securing injectors to fuel
rail and remove fuel injectors.
12.Remove and discard 2 'O' rings from each
injector.
13.Fit protective caps to each end of injectors.

FUEL DELIVERY SYSTEM - PETROL
19-2-40 REPAIRS
Refit
1.Remove protective caps from each injector.
2.Clean injectors and recesses in fuel rail and
inlet manifold.
3.Lubricate new 'O' ring with castor oil and fit to
injector.
4.Fit injectors to fuel rail and secure with spring
clips.
5.Position fuel rail assembly and connect injector
multiplugs.
6.Fit injector spacer.
7.Push each injector into inlet manifold.
8.Fit bolts securing fuel rail to inlet manifold and
tighten to 8 Nm ( 6 lbf.ft).
9.Connect fuel feed hose to fuel rail.
10.Fit engine oil dipstick.
11.Connect vacuum pipe to fuel pressure regulator
and secure with clip.
12.Connect battery earth lead.
Actuator unit - cruise control - KV6 - non
NAS
$% 19.75.05
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Disconnect vacuum hose from actuator.
4.Remove nut securing actuator to mounting
bracket.
5.Release operating rod from throttle cam and
remove actuator.
Refit
1.Position actuator and connect operating rod to
throttle cam.
2.Position actuator into mounting bracket, fit and
tighten nut.
3.Connect vacuum hose to actuator.
4.Check pull rod to retainer clearance, with lever
fully returned, pull rod should just be held by
retainer.
5.Release retainer by turning anti-clockwise,
eliminate clearance then rotate retainer half
turn clockwise. Check pull rod is just held and
rotate retainer a further quarter turn clockwise
to lock.
6.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
7.Connect battery earth lead.

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-23
23.Fit CKP sensor, fit bolt and tighten to 9 Nm (7
lbf.ft).
24.Position fluid cooler, tighten M12 bolts to 85 Nm
(63 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).
25.Clean fluid cooler unions.
26.Lubricate new 'O' rings with clean transmission
fluid and fit 'O' rings to fluid cooler hoses.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
27.Connect fluid cooler hoses to gearbox and
tighten unions to 18 Nm (13 lbf.ft).
28.Clean exhaust manifold and mating face on
cylinder head.
29.Fit exhaust manifold gasket.
30.Position exhaust manifold, fit nuts and
progressively tighten, from centre outwards to
45 Nm (33 lbf.ft).
31.Connect HO2S multiplug and secure to support
bracket.
32.Position IRD cooling hose retainer, fit bolt and
tighten to 25 Nm (18 lbf.ft).
33.Align marks on drive plate to torque converter.
34.Fit bolts securing drive plate to torque converter
and tighten bolts to 45 Nm (33 lbf.ft).
35.Clean torque converter access plate.
36.Position access plate, fit bolts and tighten to 9
Nm (7 lbf.ft).
37.Clean end of drive shaft and mating splines in
gearbox.
38.Fit new circlip to LH drive shaft.
39.With assistance pull hub outwards, align drive
shaft and fit to gearbox, taking care not to
damage drive shaft oil seal.
CAUTION: Pull the drive shaft to ensure the
circlip is fully engaged and retains the shaft.
40.Fit splash shield and secure with bolts.
41.Position trunnion to selector lever, locate inner
cable through trunnion, do not tighten nut at this
stage.
42.Position selector cable to gearbox bracket and
secure with clip.
43.Adjust selector cable.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Selector cable - adjust.
44.Fit IRD.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.
45.Connect battery earth lead.
46.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
47.Untie and close bonnet.
Gearbox - Td4
$% 44.20.02.99
Remove
1.Disconnect battery earth lead.
2.Tie bonnet back in upright position.
3.Remove intake ducting assembly.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Ducting - intake assembly.
4.Remove fluid cooler.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Fluid cooler - Td4.
5.Remove starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - Td4.
6.Remove IRD.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - Td4.
7.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release inboard joint
from gearbox.
8.With assistance, pull hub outwards and remove
LH drive shaft from gearbox.
CAUTION: Pull the drive shaft horizontally
to avoid damaging the differential oil seal.

STEERING
57-10 REPAIRS
14.Remove clips from PAS oil cooler.
Refit
1.Clean cooler mounting points.
2.Fit clips to PAS cooler.
3.Fit PAS oil cooler to vehicle.
4.Connect quick release pipe fitting.
5.Align PAS pipe bracket, fit bolt and tighten to 10
Nm (7 lbf.ft).
6.Fit bolt to clip securing PAS pipe to RH turret,
tighten to 10 Nm (7 lbf.ft).
7.Fit PAS reservoir to mounting bracket.
8.Clean PAS fluid reservoir around filler cap and
fluid level indicators.
9.Fit PAS return hose to reservoir and secure
clip.
10. Td4 models: Fit intercooler outlet hose and
tighten clips.
11. Td4 models: Fit intake duct to body and duct
assembly.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Ducting - intake assembly.
12. Td4 models: Fit engine oil dipstick.
13. Fit engine acoustic cover if fitted.

+ ENGINE - Td4, REPAIRS, Cover -
engine acoustic - Up to 02.5 Model Year.
14.Connect battery earth lead.
15.Bleed PAS system.

+ STEERING, ADJUSTMENTS, Power
assisted steering (PAS) system - bleed.
Oil cooler - KV6 models
$% 57.15.11
Remove
1.Remove front bumper.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
2.Position container below PAS pipes to catch
fluid spillage.
3.Using LRT-57-044 release and disconnect
PAS hoses from oil cooler.
4.Remove 2 bolts and remove PAS fluid cooler.
Refit
1.Fit fluid cooler and tighten bolts to 10 Nm (7
lbf.ft).
2.Clean connections.
3.Connect hoses to fluid cooler.
4.Fit front bumper.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5.Bleed PAS system.

+ STEERING, ADJUSTMENTS, Power
assisted steering (PAS) system - bleed.
M57 1204
LRT-57-044