tow LAND ROVER FREELANDER 2001 Workshop Manual

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

CONTENTS
14 CONTENTS
INTERIOR TRIM COMPONENTS ............................................................. 76-3-1
REPAIRS
Sun visor ......................................................................................................................................... 76-3-1
Trim casing - rear quarter - lower - 3 door ...................................................................................... 76-3-1
Trim casing - rear quarter - lower - 5 door ...................................................................................... 76-3-2
Trim casing - rear quarter - upper - 3 door ..................................................................................... 76-3-3
Trim casing - rear quarter - upper - 5 door ..................................................................................... 76-3-4
Trim finisher - 'A' post - upper - renew ............................................................................................ 76-3-5
Trim finisher - 'B/C' post - upper - renew ........................................................................................ 76-3-6
Trim finisher - 'B' post - lower - 5 door ............................................................................................ 76-3-7
Trim casing - body side - rear - 3 door............................................................................................ 76-3-8
Console - front - up to 04MY........................................................................................................... 76-3-9
Console assembly - front - from 04MY ........................................................................................... 76-3-11
Console - rear ................................................................................................................................. 76-3-12
Cup holder - fascia - from 04MY ..................................................................................................... 76-3-13
Fascia - up to 04MY........................................................................................................................ 76-3-14
Fascia - from 04MY ........................................................................................................................ 76-3-19
Drink tray assembly - fascia - up to 04MY ...................................................................................... 76-3-23
Stowage box - fascia ...................................................................................................................... 76-3-23
Carpet - luggage compartment ....................................................................................................... 76-3-24
Glove box........................................................................................................................................ 76-3-25
Headlining - 3 door ......................................................................................................................... 76-3-25
Headlining - 5 door ......................................................................................................................... 76-3-27
SCREENS ................................................................................................. 76-4-1
REPAIRS
Windscreen ..................................................................................................................................... 76-4-1
Glass - body side - rear .................................................................................................................. 76-4-3
SEATS ....................................................................................................... 76-5-1
REPAIRS
Front seat ....................................................................................................................................... 76-5-1
Rear seat - LH ............................................................................................................................... 76-5-1
Rear seat - RH ............................................................................................................................... 76-5-2
Cushion & squab - rear seat - bench type - 3 door ........................................................................ 76-5-2
Cover - one piece - front seat cushion ........................................................................................... 76-5-3
Cover - rear seat cushion - RH ..................................................................................................... 76-5-4
Cover - rear seat cushion - LH........................................................................................................ 76-5-6
Cover - cushion - rear single seat - 3 door .................................................................................... 76-5-7
Finisher - seat base - front - each .................................................................................................. 76-5-8
Finisher - cushion side - front seat ................................................................................................. 76-5-9
Manual mechanism - lumbar support - front seat .......................................................................... 76-5-9
Latch - rear squab - RH ................................................................................................................. 76-5-11
Latch - rear squab - LH ................................................................................................................... 76-5-11
Cover - squab - front seat .............................................................................................................. 76-5-12
Cover - squab - rear seat - side - LH .............................................................................................. 76-5-13
Cover - squab - rear seat - RH ...................................................................................................... 76-5-14
Cover - squab - rear single seat - 3 door ....................................................................................... 76-5-16

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
03-9
Oil seals
General
Always renew oil seals which have been removed
from their working location (whether as an individual
component or as part of an assembly). NEVER use
a seal which has been improperly stored or handled,
such as hung on a hook or nail.
lCarefully examine seal before fitting to ensure
that it is clean and undamaged.
lEnsure the surface on which the new seal is to
run is free of burrs or scratches. Renew the
component if the original sealing surface cannot
be completely restored.
lProtect the seal from any surface which it has to
pass when being fitted. Use a protective sleeve
or tape to cover the relevant surface.
lCertain oil seals are coated with a protective
wax and must be fitted dry unless stated
otherwise. Where an oil seal needs to be
lubricated prior to fitment, lubricate the sealing
lips with a recommended lubricant before use to
prevent damage during initial use. On dual
lipped seals, smear the area between the lips
with grease.
lIf a seal spring is provided, ensure that it is fitted
correctly.
lPlace lip of seal towards fluid to be sealed and
slide into position on shaft. Use fitting sleeve
where possible to protect sealing lip from
damage by sharp corners, threads or splines. If
a fitting sleeve is not available, use plastic tube
or tape to prevent damage to the sealing lip.
lGrease outside diameter of seal, place square
to housing recess and press into position using
great care, and if possible a 'bell piece' to
ensure that seal is not tilted. Never let weight of
unsupported shaft rest in seal.lUse the recommended service tool to fit an oil
seal. If the correct service tool is not available,
use a suitable tube approximately 0.4 mm
(0.015 in.) smaller than the outside diameter of
the seal. Use a hammer VERY GENTLY on
drift if a suitable press is not available.
lPress or drift the seal in to the depth of its
housing with the sealing lip facing the lubricant
to be retained if the housing is shouldered, or
flush with the face of the housing where no
shoulder is provided. Ensure that the seal does
not enter the housing in a tilted position.

GENERAL INFORMATION
03-15
Fuel System Hoses
All fuel hoses are made up of two laminations, an
armoured rubber outer sleeve and an inner viton
core. If any of the fuel system hoses have been
disconnected, it is imperative that the internal bore is
inspected to ensure that the viton lining has not
become separated from the armoured outer sleeve.
A new hose must be fitted if separation is evident.
Cooling system hoses
The following precautions MUST be followed to
ensure that integrity of cooling hoses and their
connections to system components are maintained.
Hose orientation and connection
Correct orientation of cooling hoses is important in
ensuring that the hose does not become fatigued or
damaged through contact with adjacent
components.
Where 'timing' marks (2) are provided on the hose
and corresponding connection, these must be used
to ensure correct orientation.Hoses must be pushed fully onto their connection
points. Usually, a moulded form (3) on the stub pipe
provides a positive indicator.
Hose clips
Markings (4) are usually provided on the hose to
indicate the correct clip position. If no markings are
provided, position the clip directly behind the
retaining lip at the end of the stub as shown.
Worm drive clips should be oriented with the crimped
side of the drive housing (5) facing towards the end
of the hose, or the hose may become pinched
between the clip and the stub pipe retaining lip.
Worm drive clips should be tightened to 3 Nm (2
lbf.ft) unless otherwise stated.
Ensure that hose clips do not foul adjacent
components.

GENERAL INFORMATION
03-23
WARNING: For front seat buckle type pre-
tensioners, hold by the piston tube, with the open
end of the piston tube pointing towards the
ground and the buckle facing away from your
body. Do not cover the end of the piston tube.
DO NOT hold buckle pre-tensioners by the
bracket assembly or steel cable. NEVER point
the piston tube towards your body or other
people.
CAUTION: Do not apply grease or cleaning
solvents to seatbelt pre-tensioner units,
component failure could result.Storage
There are regulations for the safe storage of SRS
components which must be observed, consult your
local authority for details.
WARNING: Airbag modules and seat belt pre-
tensioners are classed as explosive devices. For
overnight and longer term storage, they must be
stored in a secure steel cabinet which has been
approved as suitable for the purpose and has
been registered by the local authority.
WARNING: Store the airbag module with the
deployment side uppermost. If it is stored
deployment side down, accidental deployment
will propel the airbag module with enough force
to cause serious injury.
CAUTION: Improper handling or storage can
internally damage the airbag module, making it
inoperative. If you suspect the airbag module has
been damaged, install a new module and refer to
the Deployment/Disposal Procedures for
disposal of the damaged module.
Always observe the following precautions when
temporarily storing an airbag module:
lEnsure the cover is facing upwards and the
luggage compartment is secured.
lAlways keep components cool, dry and free
from contamination.
lDo not allow anything to rest on the airbag
module.
lStore any removed airbag assembly on a
secure flat surface away from electrical
equipment and heat sources (exceeding 85° C
(185° F).

GENERAL INFORMATION
03-26
Rotary coupler
A - Refer to the Workshop Manual for detailed
instructions.B - Ensure wheels are in the straight
ahead position before removal and refitting.C -
LAND ROVER Part Number/Bar code - The code
must be recorded and quoted for ordering purposes.
Front seat belt pre-tensioners
A warning label is fixed to the piston tube of the front
seat belt pre-tensioners:
lExercise caution.
lRefer to the publication where the procedures,
instructions and advice can be found (usually
Workshop Manual or Owner's Handbook) for
working on SRS system components.
lDo not attempt to repair or disassemble.Bar codes
Driver's airbag module
Bar codes are fitted to SRS system components and
components which are critically related to SRS
operation. The code number(s) must be recorded if
the component is to be replaced. Components
featuring bar codes include the following:
lDriver's front airbag module – label attached to
rear of module housing.
lPassenger front airbag module – label attached
to rear of module housing.
lRotary coupler – label attached on face of rotary
coupler.
lDCU – included on label on top of DCU.
lSRS wiring – label attached around harness
wires.
VEHICLE RECOVERY
Observe the following procedures for vehicle towing
after a collision has taken place:
Towing – SRS components not deployed
Normal towing procedures are unlikely to cause an
SRS module to deploy. However, as a precaution,
switch the ignition off and then disconnect both
battery leads. Disconnect the negative '-' lead first.
Towing – SRS components deployed
Once the driver's airbag has been deployed, the
vehicle must have a front suspended tow. However,
as a precaution, switch the ignition off and then
disconnect both battery leads. Disconnect the
negative '-' lead first.

GENERAL DATA
04-7
Cylinder head
Material Aluminium alloy
Cylinder head warp - maximum 0.05 mm (0.002 in)
Cylinder head height:
⇒ New 118.95 - 119.05 mm (4.683 - 4.687 in.)
⇒ Reface limit 0.20 mm (0.008 in.)
Crankshaft
Crankshaft end-float 0.10 - 0.25 mm (0.004 - 0.010 in.)
⇒ Service limit 0.34 mm (0.013 in.)
Main journal diameter: 47.986 - 48.007 mm (1.8892 - 1.8900 in.)
⇒ Maximum out of round 0.010 mm (0.0004 in.)
Main journal tolerance:
⇒ Grade 1 48.000 - 48.007 mm (1.8898 - 1.8900 in.)
⇒ Grade 2 47.993 - 48.000 mm (1.8895 - 1.8898 in.)
⇒ Grade 3 47.986 - 47.993 mm (1.8892 - 1.8895 in.)
Big-end journal diameter 47.986 - 48.007 mm (1.8892 - 1.8900 in.)
⇒ Maximum out of round 0.010 mm (0.0004 in.)
Big-end journal tolerance:
⇒ Grade A 48.000 - 48.007 mm (1.8898 - 1.8900 in.)
⇒ Grade B 47.993 - 48.000 mm (1.8895 - 1.8898 in.)
⇒ Grade C 47.986 - 47.993 mm (1.8892 - 1.8898 in.)
Main bearings:
Quantity 5
Type Steel backed, aluminium/tin lined, oil grooves in upper halves, plain in
bearing caps
Clearance in bearings 0.02 - 0.05 mm (0.0008 - 0.0020 in.)
Thrust washers Halves at No.3 main bearing
Thrust washer halves thickness 2.61 - 2.65 mm (0.1028 - 1.043 in.)
Big-end bearings:
Clearance in bearings 0.021 - 0.049 mm (0.0008 - 0.0019 in.)
Big-end end-float 0.10 - 0.25 mm (0.004 - 0.010 in.)
Connecting rods:
Type Horizontally split big-end, plain small end
Distance between centres 133.05 - 133.15 mm (5.238 - 5.242 in.)
Gudgeon pins:
Type Semi-floating off-set towards thrust side
⇒ Fit in connecting rod Interference
⇒ Diameter (RED) 17.997 - 18.000 mm (0.7085 - 0.7087 in.)
⇒ Diameter (GREEN) 17.994 - 17.997 mm (0.7084 - 0.7087 in.)
⇒ Length 52.3 - 52.6 mm (2.06 - 2.07 in.) General

GENERAL DATA
04-13
⇒⇒ Grade C (Blue)*
⇒ Grade 9 57.665 - 57.659 mm (2.2703 - 2.2700 in.)
⇒⇒ Grade A (Black)
*
⇒⇒ Grade B (Yellow)*
⇒⇒ Grade C (Green)*
†
Cylinder block / bearing ladder bore diameter grades* Crankshaft big-end journal grades
Main bearings
Quantity 4
Material / type Glacier AS15 - oil grooves in upper half shells, plain lower half shells
Clearance in bearings 0.021 - 0.039 mm (0.0008 - 0.0015 in.)
Thrust washers:
⇒ Type / position Glacier AS15 - thrust washer halves at top and bottom of rear main
bearing, oil grooves in top and bottom halves
⇒ Thrust washer halves thickness 2.61 - 2.65 mm (0.103 - 0.104 in.)
Main bearing thickness:
⇒ Red 1.930 - 1.927 mm (0.0760 - 0.0759 in.)
⇒ Blue 1.927 - 1.924 mm (0.0759 - 0.0757 in.)
⇒ Green 1.924 - 1.921 mm (0.0757 - 0.0756 in.)
⇒ Yellow 1.921 - 1.918 mm (0.0756 - 0.0755 in.)
⇒ Black 1.918 - 1.915 mm (0.0755 - 0.0754 in.)
Big-end bearings
Material / Type Glacier AS15 - plain upper and lower half shells with locating tags
Clearance in bearings 0.022 - 0.040 mm (0.0009 - 0.0016 in.)
Big-end bearing thicknesses:
⇒ Red 1.803 - 1.800 mm (0.0710 - 0.0709 in.)
⇒ Blue 1.800 - 1.797 mm (0.0709 - 0.0707 in.)
⇒ Green 1.797 - 1.794 mm (0.0707 - 0.0706 in.)
⇒ Yellow 1.794 - 1.791 mm (0.0706 - 0.0705 in.)
⇒ Black 1.791 - 1.788 mm (0.0705 - 0.0704 in.)
Big-end end-float 0.19 - 0.29 mm (0.007 - 0.011 in.)
Connecting rods
Type Forged steel H-sections with horizontally split big-ends
Distance between centres 151.31 - 151.41 mm (5.957 - 5.961 in.)
Gudgeon pins
Type Semi-floating offset towards thrust side
Fit in connecting rods Interference
⇒ Diameter - Red coded 17.997 - 18.000 mm (0.7085 - 0.7087 in.)
⇒ Diameter - Green coded 17.994 - 17.997 mm (0.7084 - 0.7085 in.)
⇒ Length 52.3 - 52.6 mm (2.059 - 2.071 in.)
⇒ Clearance in piston 0.011 mm (0.0004 in.)
Pistons
Type Aluminium alloy, tin plated, thermal expansion with offset gudgeon pin
Piston diameter (at right angle to gudgeon pin and 10
mm (0.4 in. from bottom of skirt):
⇒ Grade A 79.965 - 79.980 mm (3.1482 - 3.1488 in.)
⇒ Grade B 79.981 - 79.995 mm (3.1489 - 3.1494 in.) General

GENERAL DATA
04-32
Wheels and tyres
Tyre pressures
Wheel type and size:
⇒ Standard 51/2 J x 15" steel
⇒ Option 51/2 J x 15" alloy
⇒ Option 6.0 J x 16" alloy
⇒ Option 6.0 J x 16" alloy
Tyre sizes
5
1/2 J x 15" Wheels 195/80 R15 'Multi terrain' tyre
6 J x 16" Wheels 225/55 R17 'Multi terrain' tyre
7 J x 17" Wheels 225/55 R17 'Multi terrain' tyre
Front and rear – all engine variations
⇒ Normal driving conditions (up to 4 passengers and
luggage)2.1 bar (30 lbf/in
2)
⇒ Maximum Gross Vehicle Weight 2.1 bar (30 lbf/in
2)
⇒ Towing 2.1 bar (30 lbf/in
2)