ird 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
8CONTENTS
COOLING SYSTEM - K SERIES KV6 ...................................................... 26-3-1
ADJUSTMENTS
Coolant - drain and refill.................................................................................................................. 26-3-1
REPAIRS
Cooling fan and motor ................................................................................................................... 26-3-3
Control unit - radiator cooling fan - 2002 MY On ............................................................................ 26-3-3
Radiator assembly ......................................................................................................................... 26-3-4
Thermostat ..................................................................................................................................... 26-3-6
Coolant pump ................................................................................................................................. 26-3-7
MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6 ......................... 30-3-1
REPAIRS
Front pipe - Non NAS ..................................................................................................................... 30-3-1
Front pipe - NAS ............................................................................................................................ 30-3-3
Intermediate pipe - Non NAS .......................................................................................................... 30-3-4
Intermediate pipe - NAS ................................................................................................................ 30-3-5
Tail pipe & silencer ......................................................................................................................... 30-3-6
Heat shield - A/C compressor - KV6 - NAS .................................................................................... 30-3-7
Gasket - inlet manifold - LH ............................................................................................................ 30-3-8
Gasket - exhaust manifold - RH - Non NAS ................................................................................... 30-3-9
Gasket(s) - exhaust manifold - RH - KV6 - NAS ............................................................................ 30-3-10
Gasket - exhaust manifold - LH - Non NAS .................................................................................... 30-3-11
Gasket(s) - exhaust manifold - LH - NAS ....................................................................................... 30-3-12
Seals - inlet manifold chamber - up to 03MY .................................................................................. 30-3-13
Seals - inlet manifold chamber - from 03MY................................................................................... 30-3-18
Gasket - inlet manifold - RH............................................................................................................ 30-3-23
OVERHAUL
Seals - manifold chamber - up to 03MY ........................................................................................ 30-3-25
Seals - manifold chamber - from 03MY ......................................................................................... 30-3-27
INTERMEDIATE REDUCTION DRIVE ..................................................... 41-1
ADJUSTMENTS
Intermediate reduction drive (IRD) fluid - drain & refill - Non NAS.................................................. 41-1
Intermediate reduction drive (IRD) lubrication system - drain & refill - NAS .................................. 41-2
REPAIRS
Intermediate reduction drive (IRD) unit - Td4 ................................................................................. 41-3
Intermediate reduction drive (IRD) unit - K1.8 ................................................................................ 41-7
Intermediate reduction drive (IRD) unit - KV6 ................................................................................. 41-10
Gasket - end cover - IRD housing - Td4 ........................................................................................ 41-14
Gasket - end cover - IRD housing - KV6 ...................................................................................... 41-15
Gasket - end cover - IRD housing - K1.8 ....................................................................................... 41-18
Seals - primary gear shaft ............................................................................................................. 41-19
Seal - pinion gear .......................................................................................................................... 41-21
Seal - driveshaft - LH - Td4 & KV6 models ..................................................................................... 41-23
Seal - drive shaft - LH - K1.8 .......................................................................................................... 41-24
Seal - driveshaft - RH .................................................................................................................... 41-25
Seal - pinion gear housing - Td4..................................................................................................... 41-25
Seal - pinion gear housing - K1.8 ................................................................................................... 41-27
Seal - pinion gear housing - KV6 - Non NAS .................................................................................. 41-28
Seal - pinion gear housing - KV6 - NAS ........................................................................................ 41-30

GENERAL DATA
04-21
Manual Gearbox - Getrag
Type Getrag 282
Gears 5 forward, 1 reverse, all synchromesh
Gear ratios:
⇒ First
⇒ Second
⇒ Third
⇒ Fourth
⇒ Fifth
⇒ Reverse3.577 : 1
1.887 : 1
1.192 : 1
0.848 : 1
0.686 : 1
3.308 : 1
Final drive ratio: 3.182 : 1

GENERAL DATA
04-22
Manual Gearbox - PG1
Gear ratios:
⇒ First 3.250 : 1 (19.902 : 1 overall)
⇒ Second 1.894 : 1 (11.598 : 1 overall)
⇒ Third 1.222 : 1 (7.483 : 1 overall)
⇒ Fourth 0.848 : 1 (5.019 : 1 overall)
⇒ Fifth 0.649 : 1 (3.974 : 1 overall)
⇒ Reverse 3.000 : 1
Reverse idler gear to selector fork clearance 0.5 to 1.1 mm (0.020 - 0.043 in)
Selector fork prong width 13.0 to 13.3 mm (0.512 - 0.524 in)
Selector fork groove to pin clearance:
⇒ Standard 0.05 to 0.35 mm (0.002 - 0.014 in)
⇒ Service limit 0.50 mm (0.020 in)
Selector fork groove width 7.05 to 7.25 mm (0.278 - 0.285 in)
Gearshift arm to guide clearance:
⇒ Standard 0.20 to 0.30 mm (0.008 - 0.012 in)
⇒ Service limit 0.55 mm (0.022 in)
Interlock shift guide groove width 8.10 to 8.20 mm (0.319 - 0.323 in)
Synchro ring to gear clearance:
⇒ Standard 0.85 to 1.10 mm (0.033 - 0.043 in)
⇒ Service limit (minimum clearance) 0.40 mm (0.016 in)
Selector shaft forks in synchro sleeve grooves
clearance:
⇒ Standard 0.45 to 0.65 mm (0.018 - 0.026 in)
⇒ Service limit 1.00 mm (0.039 in)
Gearshift arm guide to selector fork clearance:
⇒ Standard 0.20 to 0.50 mm (0.008 - 0.020 in)
⇒ Service limit 0.80 mm (0.031 in)
Gearshift arm guide tongue width 11.90 to 12.00 mm (0.469 - 0.472 in)
Gearshift arm guide to interlock assembly clearance:
⇒ Standard 0.05 to 0.35 mm (0.002 - 0.014 in)
⇒ Service limit 0.60 mm (0.024 in)
Gearshift arm guide groove width 13.05 to 13.25 mm (0.514 - 0.522 in)
Interlock ball to gearshift arm guide clearance:
⇒ Standard 0.05 to 0.25 mm (0.002 - 0.010 in)
⇒ Service limit 0.50 mm (0.020 in)
Interlock ball outside diameter 12.05 to 12.15 mm (0.474 - 0.478 in)
2nd to 3rd gear clearance:
⇒ Standard 0.06 to 0.21 mm (0.002 - 0.008 in)
⇒ Service limit 0.30 mm (0.012 in)
3rd gear thickness:
⇒ Standard 35.42 to 35.47 mm (1.394 - 1.396 in)
⇒ Service limit 35.30 mm (1.390 in)

GENERAL DATA
04-24
Intermediate Reduction Drive (IRD)
Ratios:
⇒IRD input shaft to IRD countershaft 0.828 : 1
⇒ IRD countershaft to Front driveshaft 1.762 : 1
⇒ IRD countershaft to Propeller shaft 0.553 : 1
IRD ratio:
⇒ Td4 engines
⇒ K1.8 engines
⇒ KV6 engines1.467 : 1
1.467 : 1
1.359 : 1
Oil cooler Connected to vehicle cooling system

GENERAL DATA
04-25
Automatic Gearbox - Jatco
Gear Ratios - Td4 engine:
⇒ First 3.801:1
⇒ Second 2.131:1
⇒ Third 1.364:1
⇒ Fourth 0.935:1
⇒ Fifth 0.685:1
⇒ Reverse 2.970:1
Gear ratios - KV6 engine
⇒ First 3.474 : 1
⇒ Second 1.948 : 1
⇒ Third 1.247 : 1
⇒ Fourth 0.854 : 1
⇒ Fifth 0.685 : 1
⇒ Reverse 2.714 : 1
Final drive ratio:
⇒ Td4 engine
⇒ KV6 engine2.91 : 1
3.66 : 1
Torque converter lock-up
Td4
KV6Engaged in fourth and fifth gears.
50% throttle - 80 Kph (50 mph) in normal drive mode
50% throttle - 110 Kph (69 mph) in normal drive mode

IDENTIFICATION NUMBERS
05-3
Td4 engines
Manual gearbox number
PG1 gearbox serial number is provided on a bar
code label attached to the front face of the clutch
housing.
PG1 gearbox
Getrag gearbox serial number is provided on an
adhesive bar code label attached to the gearbox
casting.Getrag gearbox
Automatic gearbox number
The JATCO automatic gearbox serial number is
stamped on the upper RH side of the gearbox casing.
JATCO automatic gearbox
IRD unit
The IRD unit serial number is provided as a bar code
on an adhesive label applied to the IRD casing.

IDENTIFICATION NUMBERS
05-4
IRD unit

TORQUE WRENCH SETTINGS
06-6
Engine – KV6
TORQUE DESCRIPTION METRIC IMPERIAL
Bearing ladder to cylinder block bolts
†
⇒ Stage 120 Nm 15 lbf.ft
⇒ Stage 2+90 °+90 °
Camshaft carrier to cylinder head bolts
†++10 Nm 7.5 lbf.ft
Camshaft cover to carrier bolts
†9 Nm 7 lbf.ft
Camshaft timing belt cover bolts 4 Nm 3 lbf.ft
Camshaft timing belt front cover backplate to cylinder head bolts
+9 Nm 7 lbf.ft
Camshaft timing belt rear cover backplate to cylinder head bolts
+9 Nm 7 lbf.ft
Camshaft timing belt tensioner bolts 25 Nm 18 lbf.ft
Camshaft timing gear bolts *
⇒ Stage 127 Nm 20 lbf.ft
⇒ Stage 2+90 °+90 °
Camshaft position sensor bracket to camshaft cover bolt 9 Nm 7 lbf.ft
Connecting rod big-end bolts
⇒ Stage 120 Nm 15 lbf.ft
⇒ Stage 2+45 °+45 °
Crankcase (lower) to cylinder block bolts
⇒ M6 bolts
+++25 Nm 7 lbf.ft
⇒ M8 bolts
+++25 Nm 18 lbf.ft
Crankshaft pulley bolt 160 Nm 118 lbf.ft
Crankshaft rear oil seal to cylinder block bolts
* † 8 Nm 6 lbf.ft
Cylinder head bolts
†
⇒ Stage 125 Nm 18 lbf.ft
⇒ Stage 218 lbf.ft 18 lbf.ft
⇒ Stage 325 Nm 18 lbf.ft
⇒ Stage 4+180 °+180 °
Drain plug to sump 25 Nm 18 lbf.ft
Drive plate to crankshaft bolts
†
⇒ Stage 1
⇒ Stage 225 Nm
100 Nm18 lbf.ft
74 lbf.ft
Earth lead to RH camshaft cover bolt 9 Nm 7 lbf.ft
Engine front mounting plate to cylinder block and IRD bracket
⇒ M10 bolt - No. 1 on tightening sequence 25 Nm 18 lbf.ft
⇒ M10 bolt - No. 5 on tightening sequence 45 Nm 33 lbf.ft
⇒ M12 bolts85 Nm 63 lbf.ft
Engine mounting bracket to engine front plate bolts 45 Nm 33 lbf.ft
Engine mounting (LH) to body bolts 45 Nm 33 lbf.ft
Engine mounting bracket (LH) to gearbox bracket through bolt 85 Nm 63 lbf.ft
Engine mounting bracket (LH) to gearbox bracket through bolt 100 Nm 74 lbf.ft
Engine steady (lower) to sump bracket and subframe bolts 100 Nm 74 lbf.ft
Engine steady (upper RH) to body bolts 100 Nm 74 lbf.ft
Engine steady (upper RH) to top arm bolt 100 Nm 74 lbf.ft
Fuel rail to inlet manifold bolts 9 Nm 7 lbf.ft
Heat shield (RH rear timing belt) to cylinder head bolts
⇒ M69 Nm 7 lbf.ft
⇒ M825 Nm 18 lbf.ft
Hydramount (RH)85 Nm 63 lbf.ft
Idler pulley to engine front mounting plate Allen bolt 45 Nm 33 lbf.ft

TORQUE WRENCH SETTINGS
06-7
† Tighten in sequence
*New bolts must be fitted
+ Apply sealant, Part No. STC50552 to threads
++ Apply sealant, Part No. STC 4600 to threads
+++ Apply sealant, Part No. STC 50550 to threads
Ignition coils to LH inlet manifold nut and bolts 9 Nm 7 lbf.ft
Ignition plug top coils to spark plug bolts 9 Nm 7 lbf.ft
Inlet manifold to cylinder head nuts and bolts 25 Nm 18 lbf.ft
IRD support bracket to front mounting plate bolts 45 Nm 33 lbf.ft
IRD support bracket to sump bolts 45 Nm 33 lbf.ft
LH mounting to body bolts 48 Nm 35 lbf.ft
LH mounting bracket to gearbox bolts 85 Nm 63 lbf.ft
LH mounting to gearbox bracket through bolt 100 Nm 74 lbf.ft
Oil cooler to sump mounting bracket nuts 25 Nm 18 lbf.ft
Oil cooler pipes to oil filter and oil cooler unions 26 Nm 19 lbf.ft
Oil dipstick tube bracket to cylinder block bolt 9 Nm 7 lbf.ft
Oil pick-up strainer to bearing ladder bolts
+8 Nm 6 lbf.ft
Oil pressure relief valve plug nut
+25 Nm 18 lbf.ft
Oil pressure switch 14 Nm 10 lbf.ft
Oil pump to cylinder block bolts
†
⇒ Stage 1
⇒ Stage 25 Nm
9 Nm4 lbf.ft
7 lbf.ft
PAS pipe to engine front mounting plate bolt 25 Nm 18 lbf.ft
PAS pipe support bracket to RH hydramount nut 85 Nm 63 lbf.ft
Sump to lower crankcase bolts
†++35 Nm 26 lbf.ft
Timing belt cover (front LH and RH) bolts 4 Nm 3 lbf.ft
Timing belt cover (lower) to cylinder block bolts 9 Nm 7 lbf.ft
Timing belt cover (rear LH and RH) bolts 4 Nm 3 lbf.ft
Rear timing belt cover backplate bolts 9 Nm 7.5 lbf.ft
Top arm to RH hydramount nut 85 Nm 63 lbf.ft
Top arm bracket to engine front plate and RH mounting bolts 100 Nm 74 lbf.ft