transmission oil LAND ROVER FREELANDER 2001 Workshop Manual

CONTENTS
6CONTENTS
EMISSION CONTROL ............................................................................. 17-1-1
ADJUSTMENTS
Evaporative loss control system (EVAPS) - leak test - NAS........................................................... 17-1-1
REPAIRS
Valve - depression limiter - Td4 ..................................................................................................... 17-1-3
Solenoid - canister purge - KV6 ...................................................................................................... 17-1-4
Charcoal canister - petrol - Non NAS ............................................................................................. 17-1-4
Charcoal canister - NAS ................................................................................................................. 17-1-5
Valve - canister purge - K1.8 .......................................................................................................... 17-1-6
Valve - EGR - Td4 .......................................................................................................................... 17-1-7
Solenoid/modulator valve - EGR - Td4 ........................................................................................... 17-1-8
Thermal valve - exhaust gas recirculation (EGR) -
Td4 Automatic transmission (hot climates) - from 03 MY ............................................................... 17-1-9
Cooler - EGR - Td4 ......................................................................................................................... 17-1-9
Module - tank leakage diagnostic (DMTL) ...................................................................................... 17-1-11
Filter - fuel leak detection pump - KV6 - NAS ................................................................................ 17-1-12
Catalytic converter - RH - KV6 - NAS ............................................................................................ 17-1-12
ENGINE MANAGEMENT SYSTEM - SIEMENS....................................... 18-3-1
REPAIRS
Spark plugs - up to 03MY ............................................................................................................... 18-3-1
Spark plugs - from 03MY ................................................................................................................ 18-3-2
Coil - each - LH bank - up to 03MY ................................................................................................ 18-3-3
Coil - each - LH bank - from 03MY ................................................................................................. 18-3-3
Coil - each - RH bank - up to 03MY ................................................................................................ 18-3-4
Coil - each - RH bank - from 03MY................................................................................................. 18-3-4
Engine control module (ECM) - Non NAS ..................................................................................... 18-3-5
Engine control module (ECM) - fuel - NAS .................................................................................... 18-3-6
Idle Air Control Valve (IACV) ......................................................................................................... 18-3-7
Sensor - intake air temperature (IAT) - NAS .................................................................................. 18-3-8
Sensor - engine coolant temperature (ECT) .................................................................................. 18-3-8
Sensor - crankshaft position (CKP) ............................................................................................... 18-3-9
Sensor - throttle position (TP) ......................................................................................................... 18-3-10
Sensor - thermostat monitoring (TM) - KV6 - NAS ........................................................................ 18-3-11
Sensor - camshaft position (CMP) ................................................................................................. 18-3-12
Sensor - knock (KS) ....................................................................................................................... 18-3-13
Switch - throttle pedal - Non NAS ................................................................................................... 18-3-13
Sensor - combined - manifold absolute pressure/Intake air temperature (MAP/IAT) ..................... 18-3-14
Sensor - throttle position (TP) - NAS - up to 03MY......................................................................... 18-3-15
Sensor - throttle position (TP) - NAS - from 03MY ......................................................................... 18-3-16

GENERAL INFORMATION
03-21
It should be noted that these precautions are not
restricted to operations performed when servicing
the SRS system, the same care should be exercised
when working on ancillary systems and components
located in the vicinity of SRS components; these
include but are not limited to:
lSteering system – steering wheel airbag,
rotary coupler.
lFront fascia – passenger front airbag (where
fitted); SRS DCU behind centre console, on
transmission tunnel under the HeVAC system.
lFront seats – seat belt pre-tensioners, integral
with seat belt buckle assembly.
lElectrical system – SRS harnesses, link leads
and connectors.
Making the SRS system safe
Before working on or in the vicinity of SRS
components, ensure the system is rendered safe by
performing the following procedures:
lRemove the ignition key from the ignition switch.
lDisconnect both battery leads, earth lead first.
lWait 10 minutes for the SRS DCU back-up
power circuit to discharge.
The SRS system uses energy reserve capacitors
that keep the system active in the event of electrical
supply failure under crash conditions. It is necessary
to allow the capacitor sufficient time to discharge (10
minutes) in order to avoid the risk of accidental
deployment.
WARNING: Always disconnect both battery leads
before beginning work on the SRS system.
Disconnect the negative battery lead first. Never
reverse connect the battery.Installation
In order to assure system integrity, it is essential that
the SRS system is regularly checked and maintained
so that it is ready for effective operation in the event
of a collision. Carefully inspect SRS components
before installation. Do not install a part that shows
signs of being dropped or improperly handled, such
as dents, cracks or deformation.
WARNING: The integrity of SRS system
components is critical for safety reasons. Ensure
the following precautions are always adhered to:
lNever install used SRS components from
another vehicle or attempt to repair an SRS
component.
lWhen repairing an SRS system only use
genuine new parts.
lNever apply electrical power to an SRS
component unless instructed to do so as
part of an approved test procedure.
lSpecial Torx bolts are necessary for
installing the airbag module — do not use
other bolts. Ensure bolts are tightened to the
correct torque.
lAlways use new fixings when replacing an
SRS component.
lEnsure the SRS Diagnostic Control Unit
(DCU) is always installed correctly. There
must not be any gap between the DCU and
the bracket to which it is mounted. An
incorrectly mounted DCU could cause the
system to malfunction.
CAUTION: Ensure SRS components are not
contaminated with oil, grease, detergent or
water.
Ensure that SRS component fixings are correctly
positioned and torqued during service and repair.
CAUTION: Torque wrenches should be regularly
checked for accuracy to ensure that all fixings
are tightened to the correct torque.
If you suspect an airbag assembly could be
defective, install a new unit and dispose of the old
unit. Manually deploy the old unit before disposal.

MAINTENANCE
10-28 MAINTENANCE
Steering
Check
1.Check/tighten steering unit and steering rod
ball joint fixings.
2.Check condition of ball joints and dust covers.
3.Check steering rack bellows for any signs of
leakage.
Road Test
There are two purposes for conducting a road test.
Firstly, to ensure the work completed within the
dealership meets the standards required as laid
down by dealership processes. Secondly, for a
skilled technician to assess the general condition of
the vehicle and report any conditions that the
customer should be made aware of.
CAUTION: Two wheel dynamometer tests must
not be carried out. Four wheel dynamometer
tests must be restricted to 3 mph (5 kph).
Engine Start
1.Check for correct operation of starter switch.
Ensure the engine starts in a correct manner.
Leave the engine running.
Starter Inhibitor Switch – (Automatic only)
1.Select 'D' gear lever position.
2.Check that engine will not start.
3.Select 'R' gear lever position and repeat start
check.
4.Check that engine will start in 'P' and 'N'
positions.
Selector Cable – (Automatic only)
1.Check for correct setting of gear selector cable.
Engine Performance and Throttle Operation
1.Start engine and check that it starts easily.
2.Check that 'oil pressure' and 'no charge'
warning lamps extinguish.
3.Check that throttle pedal movement is free and
unrestricted.
4.Check that engine is responsive to throttle
movement.
Clutch and Gear Selection –
(Manual only, normal driving conditions)
1.Check that clutch engages smoothly without
judder, slipping or noise.
2.Check for abnormal transmission noise.
3.Check for smooth quiet gear changes and that
gear selected engages easily.

INTERMEDIATE REDUCTION DRIVE
41-2 ADJUSTMENTS
Intermediate reduction drive (IRD)
lubrication system - drain & refill - NAS
$% 41.25.06
Drain
1.Remove underbelly panel

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
2.Place container beneath IRD unit.
WARNING: Observe due care when draining
gearbox fluid as the fluid can be very hot.
3.Clean area around filler/level and drain plugs.
4.Using LRT-41-021 remove filler plug and
discard sealing washer.5.Remove drain plug, discard sealing washer and
allow oil to drain.
NOTE: The fluid should be drained with the
transmission at normal operating temperature.
6.Fit new sealing washer and tighten drain plug to
35 Nm (26 lbf.ft).
Refill
1.Fill with fluid until it just runs from filler/level
hole. Allow sufficient time for fluid to flow and
reach a common level in unit.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
2.Fit new sealing washer and tighten filler/level
plug to 35 Nm (26 lbf.ft).
3.Fit underbelly panel

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
M417853
LRT-41-021
M41 7687

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-11
Oil seal - torque converter
$% 44.17.11
Remove
1.Remove gearbox assembly.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gearbox - KV6.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gearbox - Td4.
2.Remove torque converter from gearbox.
Discard 'O' ring from gearbox input shaft.
3.Remove torque converter oil seal from
gearbox. Discard torque converter oil seal.
CAUTION: When removing torque converter
oil seal take care not to damage oil pump
housing.Refit
1.Clean torque converter spigot.
2.Clean torque converter oil seal recess in
gearbox. Lubricate torque converter oil seal
with clean transmission fluid.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
3.Fit new torque converter oil seal using LRT-44-
024.
4.Lubricate and fit new 'O' ring to input shaft.
5.Fit torque converter.
6.Ensure converter is fully located in oil pump
drive by checking depth 'A' as illustrated.
lKV6 models: Depth A = 4 mm.
lTd4 models: Depth A = 27 mm.
7.Fit gearbox assembly.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gearbox - KV6.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gearbox - Td4.
M44 1659
A

AUTOMATIC GEARBOX - JATCO
44-16 REPAIRS
35.Remove 2 top bolts securing gearbox to
engine.
36.Release gearbox from 2 dowels.
37.Remove gearbox assembly.
38.Fit converter retaining plate and secure with
bolts.Refit
1.Remove torque converter retaining plate.
2.Ensure converter is fully located in oil pump
drive by checking depth 'A' as illustrated. Depth
A = 4 mm.
3.Clean gearbox to engine mating faces, dowels
and dowel holes.
4.Fit gearbox assembly.
5.Fit bolts securing gearbox and tighten to 85 Nm
(63 lbf.ft).
6.Disconnect lifting equipment.
7.Clean CKP sensor and mating face.
8.Fit CKP sensor, fit bolt and tighten to 9 Nm (7
lbf.ft).
9.Position fluid cooler, tighten M12 bolts to 85 Nm
(63 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).
10.Connect hoses to fluid cooler.
11.Clean fluid cooler unions.
12.Lubricate new 'O' rings with clean transmission
fluid and fit 'O' rings to fluid cooler hoses.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
13.Connect fluid cooler hoses to gearbox and
tighten unions to 18 Nm (13 lbf.ft).
14.Clean starter motor mating faces.
15.Position starter motor to gearbox, align CKP
sensor multiplug bracket, fit and tighten bolts to
45 Nm (33 lbf.ft).
16.Using gearbox bracket bolts, secure LRT-44-
026 lifting bracket to gearbox.
17.Position IRD cooling hose retainer, fit bolt and
tighten to 25 Nm (18 lbf.ft).
18.Align marks on drive plate to torque converter.
19.Fit bolts securing drive plate to torque converter
and tighten bolts to 45 Nm (33 lbf.ft).
20.Clean torque converter access plate.
M44 1689
A
M44 1668

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

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

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

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

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

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

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

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

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

DRIVESHAFTS
REPAIRS 47-7
10.With assistance pull hub assembly outwards
and release drive shaft outer joint from hub
assembly.
11.Taking care not to damage 'Flinger', release
drive shaft inner joint from differential using
LRT-51-014 and remove drive shaft.
12.Remove and discard drive shaft circlip.Refit
1.Inspect differential seal, renew if worn or
damaged.
2.Clean ends of drive shaft and locations in hub
and differential.
3.Lubricate oil seal running surface with
transmission oil.
4.Fit new circlip to drive shaft.
5.Fit drive shaft to differential and push fully
home.
CAUTION: Pull the drive shaft to ensure the
circlip is fully engaged and retains the shaft.
6.With assistance fit drive shaft to hub.
7.Fit new drive shaft nut but do not tighten at this
stage.
8.Fit nut, bolt and dynamic damper to adjustable
transverse link and tighten to 120 Nm (89 lbf.ft).
CAUTION: Nuts and bolts must be tightened
with the weight of the vehicle on the
suspension.
9.Fit nut and bolt to fixed transverse link and
tighten to 120 Nm (89 lbf.ft).
10.Fit spacer, nut and bolt to trailing link and
tighten to 120 Nm (89 lbf.ft).
11.Fit new drive shaft nut and tighten to 400 Nm
(295 lbf.ft). Stake nut to shaft.
12.Check and top up oil level.

+ MAINTENANCE, MAINTENANCE,
Rear Axle.
13.Fit road wheel(s) and tighten nuts to 115 Nm 85
lbf.ft).
14.Remove stands and lower vehicle.
15.Connect battery earth lead.

STEERING
REPAIRS 57-17
Column lock & ignition/starter switch
assembly
$% 57.40.31
Remove
1.Disconnect battery earth lead.
2.Remove starter key from ignition lock.
3.Remove steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
column.
4.Disconnect multiplugs from ignition switch and
passive coil.
5.Remove passive coil.
6.Remove 2 screws and remove ignition switch.
7.Move rubber column cover aside to access
column lock bolts.
8.Mark both column lock bolts using a centre
punch.
9.Drill out both column lock bolts.10.Remove column lock saddle and remove
column lock.
11. Models with automatic transmission:
Loosen union and release key interlock cable
from column lock.
Refit
1. Models with automatic transmission: Align
key interlock cable to column lock and tighten
union to 4 Nm (3 lbf.ft).
2.Position lock to steering column assembly and
fit shear bolts. Do not tighten shear bolts at this
stage.
3.Insert starter key, check operation of steering
lock and that key turns freely.
4.Ensure correct operation of key interlock cable.
5.Remove starter key from column lock.
6.Tighten shear bolts fully and shear heads off.
7.Position ignition switch to column, fit and
tighten screws.
8.Fit passive coil.
9.Connect multiplugs to ignition switch and
passive coil.
10. Models with automatic transmission:
Ensure correct operation of microswitch.
11.Align column cover.
12.Fit steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
column.
13.Connect battery earth lead.

STEERING
57-22 REPAIRS
Refit
1.Remove column from vice.
2.Fit new cable ties to steering column.
3. Models with automatic transmission: Fit key
interlock cable clip.
4.Position steering column to vehicle, locate
steering column on PAS rack, aligning column
coupling with PAS rack input flag.
5.Locate steering column on studs fit nuts but do
not tighten at this stage.
6.Fit bolts and snubber to pivot mountings and
tighten bolts to 14 Nm (10 lbf.ft).
7.Tighten nuts to 14 Nm (10 lbf.ft).
8.Fit and tighten PAS rack pinion clamp bolt to 32
Nm (24 lbf.ft).
CAUTION: Nuts and bolts must be tightened
with weight of vehicle on suspension.
9. Models with automatic transmission:
Remove clamp bolt from height adjuster and
position key interlock cable.
10. Models with automatic transmission: Fit
height adjuster clamp bolt and tighten nut to 10
Nm (7.5 lbf.ft). Ensure bolt and plastic stop are
correctly located in slot in column bracket.
11. Models with automatic transmission: Fit
height adjuster lever and tighten bolt 12 Nm (9
lbf.ft). Ensure lever is in the fully up position
before tightening bolt. Hold clamp bolt nut to
prevent nut rotation.
12. Models with automatic transmission:
Remove starter key from column lock.
13. Models with automatic transmission: Align
key interlock cable to column lock and tighten
union to 4 Nm (3 lbf.ft).
14. Models with automatic
transmission:Position lock to steering column
assembly and fit shear bolts. Do not tighten
shear bolts at this stage.
15. Models with automatic transmission: Insert
starter key, check operation of steering lock
and that key turns freely.
16. Models with automatic transmission:
Ensure correct operation of key interlock cable.
17. Models with automatic transmission:
Remove starter key from column lock.
18. Models with automatic transmission:
Tighten shear bolts fully and shear heads off.
19. Models with automatic transmission: Fit
passive coil.
20. Models with automatic transmission:
Position ignition switch to column, fit and
tighten screws.
21. Models with automatic transmission:
Secure key interlock cable in clip.
22. Models with automatic transmission:
Ensure key interlock cable is correctly fitted.23.Fit side support bolt and tighten to 10 Nm (7.5
lbf.ft).
24.Position harness and secure cable ties.
25.Fit fusebox cover and close glove box lid.
26.Connect multiplugs to column switch and
passive coil.
27.Fit aperture trim and secure with screws.
28. Fit steering column multi purpose switch.

+ LIGHTING, REPAIRS, Switch -
combined direction indicator/headlight/
horn.
29.Connect battery earth lead.