heating LAND ROVER FREELANDER 2001 Workshop Manual

CONTENTS
2CONTENTS
GENERAL DATA ..................................................................................... 04-1
Engine - Td4 Diesel ........................................................................................................................ 04-1
Engine - K1.8 Petrol........................................................................................................................ 04-6
Engine - KV6 Petrol ........................................................................................................................ 04-11
Fuel system - Td4 Diesel ................................................................................................................ 04-16
Fuel system - K1.8 Petrol ............................................................................................................... 04-18
Fuel system - KV6 Petrol ................................................................................................................ 04-18
Cooling system - Td4 Diesel ........................................................................................................... 04-19
Cooling system - K1.8 Petrol .......................................................................................................... 04-19
Cooling system - KV6 Petrol ........................................................................................................... 04-19
Clutch.............................................................................................................................................. 04-20
Manual Gearbox - Getrag ............................................................................................................... 04-21
Manual Gearbox - PG1 ................................................................................................................... 04-22
Intermediate Reduction Drive (IRD)................................................................................................ 04-24
Automatic Gearbox - Jatco ............................................................................................................. 04-25
Rear Axle and Final Drive ............................................................................................................... 04-26
Steering .......................................................................................................................................... 04-27
Front Suspension............................................................................................................................ 04-28
Rear Suspension ............................................................................................................................ 04-30
Brakes............................................................................................................................................. 04-31
Wheels and tyres ............................................................................................................................ 04-32
Tyre pressures ................................................................................................................................ 04-32
Heating and Ventilation................................................................................................................... 04-33
Air Conditioning .............................................................................................................................. 04-33
Electrical - Td4 engine .................................................................................................................... 04-34
Electrical - K1.8 engine ................................................................................................................... 04-34
Electrical - KV6 engine ................................................................................................................... 04-34
Dimensions ..................................................................................................................................... 04-35
Weights ........................................................................................................................................... 04-36
IDENTIFICATION NUMBERS .................................................................. 05-1
Vehicle Identification Number ......................................................................................................... 05-1
Identification Number Locations ..................................................................................................... 05-2

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

CONTENTS
18 CONTENTS
HEATING AND VENTILATION ................................................................. 80-1
REPAIRS
Controls - heater - up to 04MY ....................................................................................................... 80-1
Controls - heater - from 04MY ........................................................................................................ 80-2
Servo - air recirculation .................................................................................................................. 80-3
Switch - recirculation control .......................................................................................................... 80-3
Switch - fan - front heater .............................................................................................................. 80-4
Ventilator - face level - LH ............................................................................................................. 80-5
Plenum - air intake ......................................................................................................................... 80-6
Heater unit ..................................................................................................................................... 80-7
Element - positive temperature co-efficient (PTC) heater - Td4 models......................................... 80-10
Harness - positive temperature co-efficient (PTC) heater - Td4 models ........................................ 80-11
Microswitch - positive temperature co-efficient (PTC) heater - Td4 models ................................... 80-14
Blower assembly ............................................................................................................................ 80-14
Resistor unit - fan motor ................................................................................................................ 80-15
Matrix - heater................................................................................................................................. 80-15
Relay - power - positive temperature co-efficient (PTC) - Td4 models ........................................... 80-16
Relay - control - positive temperature co-efficient (PTC) - Td4 models .......................................... 80-17
Fuel burning heater (FBH) .............................................................................................................. 80-18
Sensor - outside temperature (OT) ................................................................................................. 80-19
Fuel pump - fuel burning heater - up to 03MY ................................................................................ 80-20
Fuel pump - fuel burning heater - from 03MY ................................................................................. 80-21
AIR CONDITIONING ................................................................................. 82-1
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING
Refrigerant recovery - recycling and recharge................................................................................ 82-1
ADJUSTMENTS
Drive belt - compressor - Td4 ......................................................................................................... 82-3
REPAIRS
Drive belt - compressor - Td4 ......................................................................................................... 82-5
Compressor - Td4 ........................................................................................................................... 82-6
Compressor - KV6 .......................................................................................................................... 82-7
Compressor - K1.8.......................................................................................................................... 82-8
Condenser ...................................................................................................................................... 82-10
Receiver drier ................................................................................................................................. 82-12
Switch - control ............................................................................................................................... 82-13
Sensor - refrigerant pressure .......................................................................................................... 82-14
Valve - thermostatic expansion (TXV) ............................................................................................ 82-15
Evaporator ..................................................................................................................................... 82-16

GENERAL INFORMATION
03-1
GENERAL INFORMATION
General precautions
Dangerous substances
Modern vehicles contain many materials and liquids
which if not handled with care can be hazardous to
both personal health and the environment.
WARNING: Many liquids and other substances
used in motor vehicles are poisonous and should
under no circumstances be consumed and
should, as far as possible, be kept from contact
with the skin. These liquids and substances
include acid, anti-freeze, asbestos, brake fluid,
fuel, windscreen washer additives, lubricants,
refrigerants and various adhesives.
Always read carefully the instructions printed on
labels or stamped on components and obey them
implicitly. Such instructions are included for
reasons of your health and personal safety.
Never disregard them.
WARNING: Many of the fluids used in motor
vehicles, such as coolant, brake fluid and power
steering fluid, are inflammable. Take care not to
spill fluids when topping-up, a fire may result. If
spillage does occur, ensure the area is
thoroughly cleaned before starting the engine.
Synthetic rubber
Many 'O' rings, seals, hoses, flexible pipes and other
similar items which appear to be natural rubber, are
in fact, made of synthetic materials called
Fluoroelastomers.
Under normal operating conditions this material is
safe and does not present a health hazard. However,
if the material is damaged by fire or excessive
heating, it can break down and produce highly
corrosive Hydrofluoric acid which can cause serious
burns on contact with skin.
If skin contact does occur:
lRemove any contaminated clothing
immediately.
lIrrigate effected area of skin with a copious
amount of cold water or limewater for 15 to 60
minutes.
lObtain medical assistance immediately.
Should any material be in a burnt or over-heated
condition, handle with extreme caution and wear
protective clothing (seamless industrial gloves,
protective apron etc.). Decontaminate and dispose of
gloves immediately after use.Lubricating oils
WARNING: Avoid excessive skin contact with used
engine oil. Used engine oil contains potentially
harmful contaminants which may cause skin cancer
or other serious skin disorders.
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats from
the skin, leading to dryness, irritation and dermatitis.
Health protection precautions
The following precautions should be observed at all
times:
lAvoid prolonged and repeated contact with oils,
particularly used engine oils.
lWear protective clothing, including impervious
gloves where practicable.
lDo not put oily rags in pockets.
lAvoid contaminating clothes (particularly those
next to the skin) with oil.
lOveralls must be cleaned regularly. Discard
heavily soiled clothing and oil impregnated
footwear.
lFirst aid treatment should be obtained
immediately for open cuts and wounds.
lUse barrier creams: apply before each work
period to help prevent lubricating oil from
contaminating the skin.
lWash with soap and water to ensure all oil is
removed (propriety skin cleansers and nail
brushes will help).
lUse moisturisers after cleaning; preparations
containing lanolin help replace the skin's natural
oils which have been removed.
lDo not use petrol, kerosene, diesel fuel, gas, oil,
thinners or solvents for cleaning skin.
lIf skin disorders develop, obtain medical advice
without delay.
lWhere practicable, degrease components prior
to handling.
lWear eye protection (e.g. goggles or face
shield) if there is a risk of eye contamination.
Eye wash facilities should be provided in the
close vicinity of the work area.

GENERAL INFORMATION
03-2
Environmental Protection Precautions
It is illegal to pour used oil on to the ground, down
sewers or drains, or into water courses.
Burning of used engine oil in small space heaters or
boilers should only be considered for units of
approved design and in compliance with the
equipment manufacturer's recommendations. The
heating system must meet the regulatory standards
of HMIP for small burners of less than 0.4 MW. If in
doubt check with the appropriate local authority and/
or manufacturer of the approved appliance.
Dispose of used oil and filters through authorised
waste disposal contractors and licensed waste
disposal sites, or through the waste oil reclamation
trade. If in doubt, contact the Local Authority for
advice on disposal facilities.
Safety instructions
Whenever possible, use a lift or pit when working
beneath vehicle, in preference to jacking. Chock
wheels as well as applying parking brake.
Jacking
Always use the recommended jacking points. The
recommended jacking points are shown in
theLIFTING AND TOWING sub-section of the
INFORMATION section.
Always ensure that any lifting apparatus has
sufficient load capacity for the weight to be lifted.
Ensure the vehicle is standing on level ground prior
to lifting or jacking.
Apply the handbrake and chock the wheels.
WARNING: Do not work on or under a vehicle
supported only by a jack. Always support the
vehicle on safety stands.
Do not leave tools, lifting equipment, spilt oil, etc.,
around or on the work bench area. Always keep a
clean and tidy work area.
Brake shoes and pads
Always fit the correct grade and specification of
brake linings. When renewing brake pads and brake
shoes always replace as complete axle sets only.

GENERAL INFORMATION
03-5
Local issues
A number of environmental issues will be of
particular concern to residents and other neighbours
close to the site. The sensitivity of these issues will
depend on the proximity of the site and the layout
and amount of activity carried on at the site.
Noise is a major concern and therefore consideration
should be given to the time spent carrying out noisy
activities and the location of those activities that can
cause excessive noise.
Car alarm testing, panel beating, hammering and
other such noisy activities should, whenever
possible, be carried out indoors with doors and
windows shut, or as far away from houses as
possible.
Running vehicle engines may be an outside activity
which could cause nuisance to neighbours because
of both noise and smell.
Be sensitive to the time of day when these activities
are carried out and minimise the time of the noisy
operation, particularly in the early morning and late
evening.
Another local concern will be the smell from the
various materials used. Using less solvent, paint and
petrol could help prevent this annoyance.
Local residents and other business users will also be
concerned about traffic congestion, noise and
exhaust fumes, be sensitive to these concerns and
try to minimise inconvenience from deliveries,
customers and servicing operations.
Checklist
Always adhere to the following:
lidentify where the neighbours who are likely to
be affected are situated;
lminimise noise, smells and traffic nuisance;
lprevent litter by putting waste in the correct
containers;
lhave waste skips emptied regularly.Use of resource
Another environmental concern is the waste of
materials and energy that can occur in day to day
activities.
Electricity for heating, lighting and compressed air
uses resources and releases pollution during its
generation.
Fuel used for heating, running cars or vans and
mobile plant is another limited resource which
consumes large amounts of energy during its
extraction and refining processes.
Water has to be cleaned, piped to site and disposed
of, all of which creates more potential pollution;
Oil, spares, paint etc., have all produced pollution in
the process of manufacture and they become a
waste disposal problem if discarded.
Checklist
Always adhere to the following:
Electricity and heating –
lkeep doors and windows closed in the winter;
lswitch off machinery or lights when not needed;
luse energy efficient heating systems;
lswitch off computers and photocopiers when
not needed.
Fuel –
ldon't run engines unnecessarily;
lthink about whether journeys are necessary and
drive to conserve fuel.
Water –
ldon't leave taps and hose pipes running;
lmend leaks quickly, don't be wasteful.
Compressed air –
ldon't leave valves open;
lmend leaks quickly;
ldon't leave the compressor running when not
needed.
Use of environmentally damaging materials –
lcheck whether a less toxic material is available.
Handling and storage of materials –
lhave the correct facilities available for handling
liquids to prevent spillage and wastage as listed
above;
lprovide suitable locations for storage to prevent
frost damage or other deterioration.

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 DATA
04-10
Sensors:
Crankshaft sensor Siemens NSC 100630, Hall effect acting on profiled target on flywheel
Camshaft sensor:
⇒ Make / Type ITT NSC 100610 +0, Hall effect acting on camshaft reluctor ring
⇒ Ring TGN 100050
Oxygen sensor:
⇒ Make / Type NTK - MHK 100720
⇒ Heating element (nominal) 7 Watts
⇒ Sensor voltage - High≈ 900 mV
⇒ Sensor voltage - Low≈ 40 mV
Throttle potentiometer:
⇒ Make / Type CTS - MJC 100020
⇒ Total track resistance 4 kΩ ± 20%
⇒ Sensor supply voltage 5V ± 4%
TMAP sensor:
⇒ Make / Type Motorola - MHK 100820
⇒ Sensor supply voltage 5V ± 4%
Coolant temperature sensor:
⇒ Make / Type AB Electronik - MEK 100170; NTC thermistor bead
Oil temperature sensor
⇒ Make / Type AB Elektronik - MEK100170; NTC thermistor bead General

GENERAL DATA
04-33
Heating and Ventilation
Air Conditioning
PTC heater - Td4 engine - if fitted
⇒ Make/Type Catem, 900 Watt output, 12 volt supply, located in Hevac unit
FBH - Td4 engine - if fitted
⇒ Make/Type Webasto Thermotop C, self-regulating, 5 kW output
System CFC free, sealed, closed-loop system
Refrigerant HFC - R134a
Refrigerant charge quantity:
All models except LHD KV6
LHD KV6 models540 ± 25 grammes
430 ± 25 grammes
Compressor, up to 04MY (some very early 04MY
vehicles may be fitted with this type of compressor):
⇒ Type Denso - variable displacement, 7-cylinder swash plate unit
⇒ High Pressure Blow-off valve 35.3 bar (3.53 MPa, 512 lbf/in
2)
⇒ Displacement (Min.) 5%
⇒ Displacement (Max.) 95%
Compressor, 04MY onwards
⇒ Type Sanden PXV16 - variable displacement, 7-cylinder swash plate unit
⇒ High Pressure Blow-off valve 35.3 bar (3.53 MPa, 512 lbf/in
2)
⇒ Displacement (Min.) 3%
⇒ Displacement (Max.) 100%
Lubricating oil Nippon Denso ND-8
Evaporator thermostat:
⇒ Opens
⇒ Closes+2 °C (+36 °F)
-4 °C (+25 °F)
Condenser fan control PWM signal from ECM to cooling fan control unit
Refrigerant Pressure Sensor
Low pressure limit:
⇒ A/C on (pressure rising) 2.25 ± 0.2 bar (32.6 ± 2.9 lbf/in
2)
⇒ A/C off (pressure falling) 1.96 ± 0.2 bar (28.4 ± 2.9 lbf/in
2)
High pressure limit:
⇒ A/C off (pressure rising) 31.4 ± 2.0 bar (455.3 ± 29 lbf/in
2)
⇒ A/C on (pressure falling) 25.5 ± 2.0 bar (369.8 ± 29 lbf/in
2)

TORQUE WRENCH SETTINGS
06-32
Heating and Ventilation
TORQUE DESCRIPTION METRIC IMPERIAL
Air intake hose and bracket assembly to fuel burning heater bolts (Td4) 10 Nm 7.5 lbf.ft
Exhaust pipe clamp bolts (Td4) 5 Nm 3.5 lbf.ft
Fuel burning heater to body bolts (Td4) 8 Nm 6 lbf.ft
Fuel burning heater to mounting bracket bolts (Td4) 8 Nm 6 lbf.ft
Heater to fascia nuts 8 Nm 6 lbf.ft
Heater to bulkhead bolt 8 Nm 6 lbf.ft
Evaporator to bulkhead bolts 8 Nm 6 lbf.ft