lock LAND ROVER FREELANDER 2001 Workshop Manual

CONTENTS
CONTENTS 1
INTRODUCTION ...................................................................................... 01-1
How To Use This Manual................................................................................................................ 01-1
Repairs and Replacements ............................................................................................................. 01-2
Specifications .................................................................................................................................. 01-2
Abbreviations and Symbols ............................................................................................................ 01-3
GENERAL INFORMATION ...................................................................... 03-1
General precautions ........................................................................................................................ 03-1
Safety instructions ........................................................................................................................... 03-2
Environmental Precautions ............................................................................................................. 03-3
General fitting instructions .............................................................................................................. 03-7
Ball and roller bearings ................................................................................................................... 03-8
Oil seals .......................................................................................................................................... 03-9
Joints and joint faces ...................................................................................................................... 03-10
Locking devices .............................................................................................................................. 03-10
Screw threads ................................................................................................................................. 03-11
Bolt identification ............................................................................................................................. 03-12
Nut identification ............................................................................................................................. 03-13
Flexible pipes and hoses ................................................................................................................ 03-14
Service tools ................................................................................................................................... 03-16
Rolling road testing ......................................................................................................................... 03-17
Fuel handling precautions ............................................................................................................... 03-18
Electrical precautions ...................................................................................................................... 03-19
Supplementary restraint system precautions .................................................................................. 03-20
SRS component manual deployment ............................................................................................. 03-27
SRS component replacement policy ............................................................................................... 03-28
Air conditioning system precautions ............................................................................................... 03-29
Remedial actions ............................................................................................................................ 03-30
Service precautions ........................................................................................................................ 03-30
Air conditioning compressor replacement ....................................................................................... 03-31

CONTENTS
4CONTENTS
MAINTENANCE ........................................................................................ 10-1
MAINTENANCE
Td4 - Diesel Engine - Under Bonnet View ...................................................................................... 10-1
K1.8 – Petrol Engine – Under Bonnet View .................................................................................... 10-2
KV6 – Petrol Engine – Under Bonnet View .................................................................................... 10-3
Seats and Seat Belts ...................................................................................................................... 10-4
Lamps, Horns and Warning Indicators ........................................................................................... 10-4
Wipers and Washers ...................................................................................................................... 10-5
Handbrake ...................................................................................................................................... 10-5
Alarm Handset Battery.................................................................................................................... 10-6
Road Wheels .................................................................................................................................. 10-6
Tyres ............................................................................................................................................... 10-7
Brake Pads and Calipers ................................................................................................................ 10-7
Brake Fluid...................................................................................................................................... 10-9
Road Wheel Speed Sensors .......................................................................................................... 10-9
Fuel Filter - Petrol ........................................................................................................................... 10-10
Fuel Filter - Diesel........................................................................................................................... 10-10
Fuel Pump and Filter assembly - Diesel - 03 Model Year onwards ................................................ 10-10
Fuel Sedimenter - Diesel - 03 Model Year onwards ....................................................................... 10-10
Door Locks, Hinges, Check Straps and Bonnet Catch ................................................................... 10-11
Anti-freeze ...................................................................................................................................... 10-12
Cooling System and Intercooler...................................................................................................... 10-12
Vent filter - turbocharger boost control solenoid valve - Td4 .......................................................... 10-13
Spark Plugs – K1.8 ......................................................................................................................... 10-13
Spark Plugs – KV6.......................................................................................................................... 10-13
Air Cleaner – Petrol Models ............................................................................................................ 10-13
Ancillary Drive Belt – Td4 ............................................................................................................... 10-14
Ancillary Drive Belt – K1.8 .............................................................................................................. 10-14
Ancillary Drive Belt – KV6 ............................................................................................................... 10-15
Camshaft Timing Belt – K1.8 .......................................................................................................... 10-15
Camshaft Timing Belt – KV6........................................................................................................... 10-16
Brake/Clutch Reservoir ................................................................................................................... 10-16
PAS Fluid Level .............................................................................................................................. 10-17
Intermediate Reduction Drive - Non NAS models .......................................................................... 10-17
Intermediate Reduction Drive - NAS models .................................................................................. 10-18
Manual Gearbox – PG1 .................................................................................................................. 10-18
Manual Gearbox – GETRAG .......................................................................................................... 10-19
Automatic Gearbox – JATCO ......................................................................................................... 10-19
Rear Axle ........................................................................................................................................ 10-20
Clutch Pipes and Unions ................................................................................................................ 10-21
Windscreen and Rear Washer Reservoir ....................................................................................... 10-21
Battery ............................................................................................................................................ 10-21
Engine Oil and Filter – Td4 ............................................................................................................. 10-22
Engine Oil and Filter – K1.8 ............................................................................................................ 10-23
Engine Oil and Filter – KV6 ............................................................................................................ 10-24
Fuel Hoses and Pipes..................................................................................................................... 10-25
Brake Hoses and Pipes ................................................................................................................. 10-26
Check Exhaust System................................................................................................................... 10-26
Suspension ..................................................................................................................................... 10-27
Steering ......................................................................................................................................... 10-28
Road Test ....................................................................................................................................... 10-28
Endorse Service Record ................................................................................................................. 10-30
Report any Unusual Features ......................................................................................................... 10-30

CONTENTS
10 CONTENTS
REAR AXLE & FINAL DRIVE ................................................................... 51-1
REPAIRS
Differential assembly ..................................................................................................................... 51-1
Cover - rear - differential ................................................................................................................. 51-2
Bush - differential mounting - front ................................................................................................. 51-3
Bush - differential mounting - rear ................................................................................................. 51-4
Oil seal - pinion .............................................................................................................................. 51-5
Oil seal - differential housing ......................................................................................................... 51-6
STEERING ................................................................................................ 57-1
ADJUSTMENTS
Power assisted steering (PAS) system - bleed............................................................................... 57-1
Cable - key interlock - adjust .......................................................................................................... 57-1
Front wheel alignment - check & adjust .......................................................................................... 57-2
Alignment - rear wheel - check & adjust ......................................................................................... 57-3
Power steering - pressure test ........................................................................................................ 57-4
REPAIRS
Power steering rack ........................................................................................................................ 57-5
Gaiter - PAS rack ............................................................................................................................ 57-8
Oil cooler - Td4 & K1.8 models ....................................................................................................... 57-9
Oil cooler - KV6 models .................................................................................................................. 57-10
Drive belt - K1.8 .............................................................................................................................. 57-11
Pump - steering - KV6 .................................................................................................................... 57-12
Pump - steering - K1.8 .................................................................................................................... 57-14
Pump - steering - Td4 ..................................................................................................................... 57-15
Nacelle - column ............................................................................................................................. 57-16
Column lock & ignition/starter switch assembly .............................................................................. 57-17
Cable - key interlock ....................................................................................................................... 57-18
Column assembly - inner & outer ................................................................................................... 57-19
Ball joint - track rod ......................................................................................................................... 57-23
Track rod......................................................................................................................................... 57-24
Steering wheel ................................................................................................................................ 57-25
FRONT SUSPENSION .............................................................................. 60-1
REPAIRS
Anti roll bar...................................................................................................................................... 60-1
Ball joint link - anti roll bar .............................................................................................................. 60-2
Mounting rubbers - anti roll bar - set .............................................................................................. 60-2
Bearing - hub ................................................................................................................................. 60-3
Damper .......................................................................................................................................... 60-7
Lower arm assembly ...................................................................................................................... 60-10
Rear beam ..................................................................................................................................... 60-13
Bush - lower arm - front .................................................................................................................. 60-15
Bush - lower arm - rear ................................................................................................................... 60-16

CONTENTS
CONTENTS 13
Remote control - front door ............................................................................................................. 76-1-30
Remote control - rear door .............................................................................................................. 76-1-30
Operating cable - lock remote control - 5 door ............................................................................... 76-1-31
Finisher - rear screen - side - 5 door .............................................................................................. 76-1-31
Handle - exterior - rear door ........................................................................................................... 76-1-32
Handle - exterior - tail door ............................................................................................................. 76-1-33
Handle - exterior - front door ........................................................................................................... 76-1-34
Door pull - 5 door - up to 04MY ....................................................................................................... 76-1-35
EXTERIOR FITTINGS ............................................................................... 76-2-1
REPAIRS
Wing - front ..................................................................................................................................... 76-2-1
Liner - front wheel arch ................................................................................................................... 76-2-2
Liner - rear wheel arch .................................................................................................................... 76-2-3
Panel - underbelly ........................................................................................................................... 76-2-4
Mirror - exterior - electric ................................................................................................................. 76-2-4
Mud flap - front ................................................................................................................................ 76-2-5
Mud flap - rear ................................................................................................................................. 76-2-5
Bracket - spare wheel mounting ..................................................................................................... 76-2-6
Side rail - integral roof rack - 5 door ................................................................................................ 76-2-7
Bonnet............................................................................................................................................. 76-2-7
Cable/rod - bonnet lock control ....................................................................................................... 76-2-8
Bumper - assembly - front - up to 04MY ......................................................................................... 76-2-10
Bumper - assembly - front - from 04MY .......................................................................................... 76-2-11
Bumper valance - rear - up to 04MY ............................................................................................... 76-2-13
Bumper valance - rear - from 04MY ................................................................................................ 76-2-13
Finisher - sill - lower ....................................................................................................................... 76-2-16
Moulding - roof - 5 door ................................................................................................................... 76-2-17
Wheelarch extension - rear wing part ............................................................................................. 76-2-18
Body quarter vent assembly - 3 door .............................................................................................. 76-2-19

CONTENTS
16 CONTENTS
PANEL REPAIRS...................................................................................... 77-2-1
BODY REPAIRS
General ........................................................................................................................................... 77-2-1
REPLACEMENT PANELS
Serviceable Panels ......................................................................................................................... 77-2-3
Inner front end panels ..................................................................................................................... 77-2-4
Outer body side panels - 3 door ..................................................................................................... 77-2-5
Outer body side panels - 5 door ..................................................................................................... 77-2-6
Front inner body side panels - 3 door ............................................................................................. 77-2-7
Front inner body side panels - 5 door ............................................................................................. 77-2-8
Rear inner body side panels - 3 door.............................................................................................. 77-2-9
Rear inner body side panels - 5 door.............................................................................................. 77-2-10
Roof assemblies - 3 door ................................................................................................................ 77-2-11
Roof assembly - 5 door................................................................................................................... 77-2-12
Rear end panels ............................................................................................................................. 77-2-13
Door assemblies ............................................................................................................................. 77-2-14
WELDING PROCEDURES
ECU locations (3 door model shown, 5 door model similar) ........................................................... 77-2-15
General Welding Precautions ......................................................................................................... 77-2-16
PROCEDURES
Panel replacement procedure......................................................................................................... 77-2-19
REPAIRS
Front bulkhead assembly ............................................................................................................... 77-2-25
Bonnet locking platform .................................................................................................................. 77-2-27
Headlamp mounting panel .............................................................................................................. 77-2-28
Front lower crossmember .............................................................................................................. 77-2-29
Front sidemember (complete) ........................................................................................................ 77-2-30
Front sidemember (front section) ................................................................................................... 77-2-32
Front valance assembly ................................................................................................................. 77-2-33
Valance upper front ....................................................................................................................... 77-2-36
Valance front .................................................................................................................................. 77-2-37
Valance outer reinforcement .......................................................................................................... 77-2-39
'A' post - 3 door .............................................................................................................................. 77-2-40
'A' post - 5 door .............................................................................................................................. 77-2-41
Sill reinforcement - 3 door .............................................................................................................. 77-2-43
Sill reinforcement - 5 door .............................................................................................................. 77-2-44
'B/C' post reinforcement - 3 door ................................................................................................... 77-2-45
'B/C' post reinforcement - 5 door ................................................................................................... 77-2-46
Complete rear quarter - 3 door ...................................................................................................... 77-2-48
Complete rear quarter - 5 door ...................................................................................................... 77-2-50
Outer rear wheel arch - 3 door ....................................................................................................... 77-2-53
Outer rear wheel arch - 5 door ....................................................................................................... 77-2-54
Inner 'e' post - 3 door ..................................................................................................................... 77-2-55
Inner 'e' post - 5 door ..................................................................................................................... 77-2-56
Rear floor crossmember assembly ................................................................................................ 77-2-58
Rear floor ........................................................................................................................................ 77-2-59
Floor longitudinal ............................................................................................................................ 77-2-60
Front roof assembly - 3 door .......................................................................................................... 77-2-61
Rear roof assembly - 3 door .......................................................................................................... 77-2-61
Roof assembly - 5 door .................................................................................................................. 77-2-62
TIMES
TIME SCHEDULES ........................................................................................................................ 77-2-63

CONTENTS
22 CONTENTS
NAVIGATION SYSTEM ............................................................................ 87-1
REPAIRS
Interface unit - remote control ........................................................................................................ 87-1
Display unit - navigation system .................................................................................................... 87-1
INSTRUMENTS ......................................................................................... 88-1
REPAIRS
Clock .............................................................................................................................................. 88-1
Instrument panel - up to 04MY ....................................................................................................... 88-2
Instrument panel - from 04MY ........................................................................................................ 88-3
Cowl - instrument - up to 04MY ...................................................................................................... 88-4
Cowl - instrument - from 04MY ....................................................................................................... 88-5
Sender unit - fuel tank gauge.......................................................................................................... 88-6
Sender unit assembly - fuel tank - Td4 models - from 03MY.......................................................... 88-6

INTRODUCTION
01-2
Repairs and Replacements
When replacement parts are required it is essential
that only Land Rover recommended parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement
parts and accessories:
lSafety features and corrosion prevention
treatments embodied in the vehicle may be
impaired if other than Land Rover
recommended parts are fitted.
lIn certain territories, legislation prohibits the
fitting of parts which are not compliant with the
manufacturer's specification.
lTorque wrench setting figures given in this
Manual must be used where specified.
lLocking devices (circlips, split pins etc.) must be
fitted where specified.
lIf a locking device is damaged during removal,
or its efficiency is impaired, it must be renewed.
lOwners purchasing accessories while travelling
abroad should ensure that the accessory and its
fitted location on the car conform to the legal
requirements of the territory.
lThe terms of the vehicle Warranty may be
invalidated by the fitting of parts other than Land
Rover recommended parts.
lAll Land Rover recommended parts have the full
backing of the vehicle Warranty.
lLand Rover Dealers are obliged to supply only
Land Rover recommended parts.
Specifications
Land Rover are constantly seeking to improve the
specification, design and production of their vehicles
and alterations take place accordingly. Whilst every
effort has been made to ensure the accuracy of this
Manual, it should not be regarded as an infallible
guide to current specifications of any particular
vehicle.
This Manual does not constitute an offer for sale of
any particular vehicle. Land Rover Dealers are not
agents of Land Rover and have no authority to bind
the manufacturer by any expressed or implied
undertaking or representation.

INTRODUCTION
01-3
Abbreviations and Symbols
A Amperes
AAP Ambient Air Pressure
AAT Ambient Air Temperature
ABDC After Bottom Dead Centre
ABS Anti-Lock Brake System
ABS / TC Anti-lock Brake System / Traction
Control
ac Alternating current
A/C Air Conditioning
ACE Active Cornering Enhancement
ACEA Association of Constructors of
European Automobiles
AFR Air Fuel Ratio
AP Ambient Pressure
ASC Anti-shunt Control
ATC Air Temperature Control
ATDC After Top Dead Centre
AUX Auxiliary
AVC Automatic Volume Control
BBDC Before Bottom Dead Centre
BBUS Battery Backed Up Sounder
BCU Body Control Unit
BDC Bottom Dead Centre
bhp Brake Horse Power
BP Boost Pressure
BPP Brake Pedal Position
BS British Standard
BTDC Before Top Dead Centre
BWD Backward
C Celsius
CAN Controller Area Network
CD Compact Disc
CDC Centre Differential Control
CDL Central Door Locking
CD - ROM Compact Disc - Read Only
Memory
CFC Chlorofluorocarbon
CHMSL Centre High Mounted Stop Lamp
CKP Crankshaft Position
CLV Calculated Load Value
cm Centimetre
cm
2Square centimetre
cm3Cubic centimetre
CMP Camshaft Position
CPP Clutch Pedal Position
CO Carbon Monoxide
CO
2Carbon Dioxide
COB Clear Over Base
CR Common Rail
CVS Canister Vent Solenoid
dB Decibels
DDM Driver's Door Module
deg. Degree, angle or temperature
DI Direct Injection
dia. DiameterDIN Deutsche Industrie Normen
(German Industrial Standards)
dc Direct current
DCV Directional Control Valve
DOHC Double Overhead Camshaft
DSP Digital Signal Processing
DTI Dial Test Indicator
DMF Dual Mass Flywheel
DVD Digital Versatile Disc
EACV Electronic Air Control Valve
EAT Electronic Automatic
Transmission
EBD Electronic Brake pressure
Distribution
ECD European Community Directive
ECM Engine Control Module
ECT Engine Coolant Temperature
ECU Electronic Control Unit
EDC Electronic Diesel Control
EEPROM Electronic Erasable
Programmable Read Only
Memory
EGR Exhaust Gas Recirculation
EKA Emergency Key Access
ELR Emergency Locking Retractor
EN European Norm
EOBD European On Board Diagnostics
EON Enhanced Other Network
ERL Electrical Reference Library
ETC Electronic Traction Control
EUI Electronic Unit Injector
EVAP Evaporative Emission
EVR Electronic Vacuum Regulator
F Fahrenheit
ft. Feet
FBH Fuel Burning Heater
FET Field Effect Transistor
FIP Fuel Injection Pump
FTC Fast Throttle Control
FWD Forward
> Greater than
g Gramme or Gravity
gal. Gallons
GMT Greenwich Mean Time
GPS Global Positioning System
hHour
hc High compression
HC Hydro Carbons
HDC Hill Descent Control
HDOP Height Dilation Of Precision
HDPE High Density Polyethylene
HFS Heated Front Screen
Hg Mercury
HO
2S Heated Oxygen Sensor
HMW High Molecular Weight

INTRODUCTION
01-4
HRW Heated Rear Window
ht/HT High tension
HSLA High Strength Low Alloy
IACV Idle Air Control Valve
IAT Intake Air Temperature
ICE In-Car Entertainment
i.dia. Internal diameter
IDM Intelligent Driver Module
IF Intermediate Frequency
in Inch
in
2Square inch
in3Cubic inch
ILT Inlet Throttle
ISO International Organisation for
Standardisation
ITS Inflatable Tubular Structure
k Thousand
kg Kilogramme
kg/h Kilogrammes per hour
km Kilometre
km/h Kilometres per hour
kPa KiloPascal
KS Knock Sensor
lLitre
lb(s) Pounds
lbf Pounds force
lbf.in Pounds force inches
lbf/in
2Pounds per square inch
lbf.ft Pounds force feet
λLambda
lc Low compression
LCD Liquid Crystal Display
LED Light Emitting Diode
LEV Low Emission Vehicle
LH Left-Hand
LHD Left-Hand Drive
LSM Light Switch Module
LVS Liquid Vapour Separator
mMetre
µMicro
MAF Mass Air Flow
MAP Manifold Absolute Pressure
MFU Multi-Function Unit
MFL Multi-Function Logic
max. Maximum
MEMS Modular Engine Management
System
MIG Metal/Inert Gas
MIL Malfunction Indicator Lamp
MPa MegaPascal
MOSFET Metal Oxide Semiconductor Field
Effect Transistor
min. Minimum
- Minus (tolerance)
' Minute (angle)
mm Millimetre
mph Miles per hour MPi Multi-Point injection
MV Motorised Valve
MY Model Year
NAS North American Specification
(-) Negative (electrical)
Nm Newton metre
No. Number
NO
2Nitrogen Dioxide
NO
xOxides of Nitrogen
NTC Negative Temperature
Coefficient
NRV Non Return Valve
OBD On Board Diagnostics
OBM On Board Monitoring
o.dia. Outside diameter
OAT Organic Acid Technology
ORM Off-road Mode
ΩOhm
PAS Power Assisted Steering
PCB Printed Circuit Board
PCV Positive Crankcase Ventilation
PDC Parking Distance Control
PDOP Position Dilation Of Precision
PI Programme Information
PPS Pulse Per Second
PS Programme Service
psi Pounds per square inch
pts. Pints
% Percentage
+ Plus (tolerance) or Positive
(electrical)
±Plus or minus (tolerance)
PTC Positive Temperature Coefficient
PTFE Polytetrafluorethylene
PWM Pulse Width Modulation
RDS Radio Data Service
rRadius
:Ratio
ref Reference
REG Regionalisation
RES Rover Engineering Standards
rev/min Revolutions per minute
RF Radio Frequency
RGB Red / Green / Blue
RH Right-Hand
RHD Right-Hand Drive
ROM Read Only Memory
RON Research Octane Number
ROV Roll Over Valve
ROW Rest Of World
SAE Society of Automotive Engineers
SAI Secondary Air Injection
" Second (angle)
SLABS Self Levelling and Anti-Lock
Brake System
SLS Self Levelling Suspension
SOHC Single Overhead Camshaft
SPE Single Point Entry

GENERAL INFORMATION
03-4
Materials –
lkeep lids on containers of solvents;
lonly use the minimum quantity;
lconsider alternative materials;
lminimise over-spray when painting.
Gases –
luse the correct equipment for collecting
refrigerants;
ldon't burn rubbish on site.
Discharges to water
Most sites will have two systems for discharging
water: storm drains and foul drains. Storm drains
should only receive clean water, foul drains will take
dirty water.
The foul drain will accept many of the normal waste
waters such as washing water, detergents and
domestic type wastes, but oil, petrol, solvent, acids,
hydraulic oil, antifreeze and other such substances
should never be poured down the drain. If in any
doubt, speak to the local Water Company first.
Every precaution must be taken to prevent spillage of
oil, fuel, solvents etc. reaching the drains. All
handling of such materials must take place well away
from the drains and preferably in an area with a kerb
or wall around it, to prevent discharge into the drain.
If a spillage occurs, it should be soaked up
immediately. Having a spill kit available will make this
easier.
Additional precautions
Check whether the surface water drains are
connected to an oil/water separator, this could
reduce the pollution if an incident was to occur. Oil/
water separators require regular maintenance to
ensure effectiveness.
Checklist
Always adhere to the following:
Disposal –
lnever pour anything down a drain without first
checking that it is environmentally safe to do so,
and that it does not contravene any local
regulations or bye-laws;
lhave oil traps emptied regularly.
Spillage prevention –
lstore liquids in a walled area;
lmake sure the taps on liquid containers are
secure and cannot be accidentally turned on;
lprotect bulk storage tanks from vandalism by
locking the valves;
ltransfer liquids from one container to another in
an area away from open drains;
lensure lids are replaced securely on containers;
lhave spill kits available near to points of storage
and handling of liquids.Spill kits
Special materials are available to absorb a number of
different substances. They can be in granular form,
ready to use and bought in convenient containers for
storage. Disposal of used spill-absorbing material is
dealt with in the 'Waste Management' section.
Land contamination
Oils, fuels and solvents etc. can contaminate any soil
that they are allowed to contact. Such materials
should never be disposed of by pouring onto soil and
every precaution must be taken to prevent spillage
reaching soil. Waste materials stored on open
ground could also leak, or have polluting substances
washed off them that would contaminate the land.
Always store these materials in suitable skips or
other similarly robust containers.
Checklist
Always adhere to the following:
ldon't pour or spill anything onto the soil or bare
ground;
ldon't store waste materials on bare ground, see
'Spillage prevention' list.
Legal compliance
Some sites may have a discharge consent for
effluent discharge to the foul drain for a car wash etc.
It is important to know what materials are allowed in
the drain and to check the results of any monitoring
carried out by the Water Company.
Where paint spraying operations are carried out it
may be necessary to apply to the Local Authority for
an air emissions licence to operate the plant. If such
a licence is in operation, additional precautions will
be necessary to comply with the requirements, and
the results of any air quality monitoring must be
checked regularly.
Checklist
Always adhere to the following:
lknow what legal consents and licences apply to
the operations;
lcheck that the emissions and discharges
comply with legal requirements.