2001 LAND ROVER FREELANDER gearbox

INTERIOR TRIM COMPONENTS
76-3-10 REPAIRS
14.Remove centre console.
15.Remove 4 screws from switch pack assembly
and remove assembly.Refit
1.Position switch pack assembly, fit and tighten
screws.
2.Position console to fascia.
3.Connect multiplugs and bulb holder to switch
pack.
4. Automatic gearbox only: Connect multiplugs
to gear selector.
5.Fit centre console.
6.Fit and tighten screws securing centre and
sides to console.
7.Fit and tighten screws securing switch pack to
console.
8.Fit and tighten screws to top of console.
9.Position radio cage to console and secure with
retaining tags.
10.Position heater control panel, fit and tighten
screws.
11.Fit heater control knobs.
12. Manual gearbox only: Fit descent selector.
13.Fit gear lever knob.
14.Fit radio.

+ IN CAR ENTERTAINMENT,
REPAIRS, Radio - up to 04MY.
15.Fit rear console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - rear.

INTERIOR TRIM COMPONENTS
REPAIRS 76-3-11
Console assembly - front - from 04MY
$% 76.25.01
Remove
1.Remove rear console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - rear.
2.Remove gear selector indicator assembly.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Selector indicator - from 04MY.
3.Carefully lever upper console finisher rearward,
to release clips on forward edge of finisher.
4.Remove 4 screws securing centre console.5.Disconnect 6 multiplugs and remove console.
NOTE: Do not carry out further dismantling if
component is removed for access only.
6.Remove switches from console, noting fitted
position.
7.Remove 4 screws securing ash tray to centre
console finisher and remove ash tray.
Refit
1.Fit switches to console.
2.Fit and secure ash tray to centre console
finisher.
3.Position console assembly and connect
multiplugs.
4.Fit console and secure with screws.
5.Align upper console finisher and secure with
clips.
6.Refit gearshift selector assembly.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Selector indicator - from 04MY.
7.Fit rear console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - rear.
M76 4695

PANEL REPAIRS
77-2-30 REPAIRS
Front sidemember (complete)
In this procedure, the front sidemember closing
panel and the related crossmember to sidemember
gusset plate are replaced in conjunction with the front
sidemember.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
6.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
7.Remove front bumper armature.
8.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
9.Remove PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
10.Remove headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
11.Release wiring to headlamp and position aside.
12.Remove engine bay shield.
13.Remove front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
14.Remove front suspension rear beam.
15.Remove engine and gearbox.

+ ENGINE - K SERIES KV6, REPAIRS,
Engine and automatic gearbox - up to 03MY.
16.Remove PAS rack.

+ STEERING, REPAIRS, Power
steering rack.
17.Remove fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
18. LH side: Remove front bumper LH support
bracket.
19. LH side: Remove LH engine mounting from
body.
20. LH side: Remove battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
21. LH side: Remove air intake hose.
22. LH side: Remove horn.

+ SECURITY, REPAIRS, Horn.
23. RH side: Remove front bumper RH support
bracket.24. RH side: Remove RH engine mounting from
body.
25. RH side: Remove windscreen washer
reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
26. Driver's side: Remove passenger
compartment fuse box.
27. Driver's side: Remove brake pedal box and
brake servo.
28. Driver's side: Remove clutch pedal box.
29.Remove treadplate from front door aperture.
Release front carpet and position aside.
30.Remove insulation pads from engine bulkhead.

PANEL REPAIRS
REPAIRS 77-2-31
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit insulation pads to engine bulkhead.
2.Position front carpet and fit treadplate to front
door aperture. 3. Driver's side: Fit clutch pedal box.
4. Driver's side: Fit brake pedal box and brake
servo.
5. Driver's side: Fit passenger compartment fuse
box.
6. LH side: Fit horn.

+ SECURITY, REPAIRS, Horn.
7. LH side: Fit air intake hose.
8. LH side: Fit battery. Do not connect battery
earth lead.

+ CHARGING AND STARTING,
REPAIRS, Battery.
9. LH side: Fit LH engine mounting to body.
10. LH side: Fit front bumper LH support bracket.
11. RH side: Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
12. RH side: Fit RH engine mounting to body.
13. RH side: Fit front bumper RH support bracket.
14.Fit fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
15.Fit PAS rack.

+ STEERING, REPAIRS, Power
steering rack.
16.Fit engine and gearbox.

+ ENGINE - K SERIES KV6, REPAIRS,
Engine and automatic gearbox - up to 03MY.
17.Fit front suspension rear beam.
18.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
19.Fit engine bay shield.
20.Fit headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
21.Secure headlamp wiring.
22.Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
23.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
24.Fit front bumper armature.
25.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
26.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
27.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
28.Connect all ECUs.
29.Connect alternator.
30.Connect battery earth lead.

PANEL REPAIRS
REPAIRS 77-2-33
Refit
1. LH side: Fit horn.

+ SECURITY, REPAIRS, Horn.
2. LH side: Fit air intake hose.
3. LH side: Fit air cleaner.
4. LH side: Fit battery carrier. Do not connect
battery earth lead.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
5. LH side: Fit ECM.
6. LH side: Fit front bumper LH support bracket.
7. RH side: Fit PAS pump.

+ STEERING, REPAIRS, Pump -
steering - KV6.
8. RH side: Fit alternator.

+ CHARGING AND STARTING,
REPAIRS, Alternator - KV6.
9. RH side: Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
10. RH side: Fit front bumper RH support bracket.
11.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
12.Fit engine bay shield.
13.Fit headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
14. Secure headlamp wiring.
15.Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
16.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
17.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
18.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
19.Connect all ECUs.
20.Connect battery earth lead.
Front valance assembly
Remove
1.Disconnect battery earth lead.
2.Disconnect all ECUs.
3.Remove road wheel(s).
4.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
6.Remove front bumper armature.
7.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
8.Remove PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
9.Remove headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
10.Release wiring to headlamp and position aside.
11.Remove engine bay shield.
12.Remove front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
13.Remove front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
14.Remove front suspension rear beam.
15.Remove engine and gearbox.

+ ENGINE - K SERIES KV6, REPAIRS,
Engine and automatic gearbox - up to 03MY.
16.Remove front damper.

+ FRONT SUSPENSION, REPAIRS,
Damper.
17.Remove PAS rack.

+ STEERING, REPAIRS, Power
steering rack.
18.Remove fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
19. LH side: Remove front bumper LH support
bracket.
20. LH side: Remove air cleaner.
21. LH side: Remove air intake hose.
22. LH side: Remove ECM.
23. LH side: Remove engine compartment
fusebox.
24. LH side: Remove battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
25. LH side: Remove engine compartment fuse
box and related wiring.

PANEL REPAIRS
77-2-34 REPAIRS
26. LH side: Remove LH engine mounting from
body.
27. LH side: On models with Diesel engines,
remove fuel filter.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Filter - main - up to 03MY.
28. LH side: Remove LH front brake pipe.
29. RH side: Remove front bumper RH support
bracket.
30. RH side: Remove windscreen washer
reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
31. RH side: Remove coolant expansion tank.
32. RH side: Remove RH engine mounting from
body.
33. RH side: Remove PAS fluid reservoir.
34. RH side: Remove RH front brake pipe.
35. Driver's side: Remove passenger
compartment fuse box.
36.Remove brake pedal box and brake servo.
37.Remove clutch pedal box.
38.Release vehicle harness from valance and
position aside.
39.Remove treadplate from front door aperture.
Release front carpet and position aside.
40.Remove insulation pads from engine bulkhead.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown. Refit
1.Fit insulation pads to front and rear sides of
engine bulkhead.
2.Position front carpet and fit treadplate to front
door aperture.
3.Secure vehicle harness to valance.
4. Driver's side: Fit clutch pedal box.
5.Fit brake pedal box and brake servo.
6.Fit passenger compartment fuse box.
7. LH side: Fit LH front brake pipe. Bleed brake
system.
+ BRAKES, ADJUSTMENTS, Brake
bleed.
8. LH side: On models with Diesel engines, fit fuel
filter.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Filter - main - up to 03MY.
9. LH side: Fit LH engine mounting to body.
10. LH side: Fit engine compartment fuse box and
related wiring.
11. LH side: Fit battery carrier. Do not connect
battery earth lead.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
12. LH side: Fit engine compartment fusebox.
13. LH side: Fit ECM.
14. LH side: Fit air intake hose.
15. LH side: Fit air cleaner.
16. LH side: Fit front bumper LH support bracket.
17. RH side: Fit RH front brake pipe. Bleed brake
system.

+ BRAKES, ADJUSTMENTS, Brake
bleed.
18. RH side: Fit PAS fluid reservoir.
19. RH side: Fit RH engine mounting to body.
20. RH side: Fit coolant expansion tank.
21. RH side: Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
22. RH side: Fit front bumper RH support bracket.
23.Fit fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
24.Fit PAS rack.

+ STEERING, REPAIRS, Power
steering rack.
25.Fit front damper.

+ FRONT SUSPENSION, REPAIRS,
Damper.
26.Fit engine and gearbox.

+ ENGINE - K SERIES KV6, REPAIRS,
Engine and automatic gearbox - up to 03MY.
27.Fit front suspension rear beam.
28.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.

HEATING AND VENTILATION
REPAIRS 80-11
Harness - positive temperature co-
efficient (PTC) heater - Td4 models
$% 80.20.06
Remove
1.Disconnect battery earth lead.
2.Remove bolt securing PTC cable from positive
side of battery.
3.Remove ECM from 'E' box.

+ ENGINE MANAGEMENT SYSTEM -
EDC, REPAIRS, Engine control module
(ECM).
4.Disconnect multiplugs from gearbox ECU and
cooling fan sensor5.Release harness from cable ties and release
relays from inner casing.
6.Release and disconnect cooling fan and joint
harness multiplugs.
7.Release 3 harnesses and air duct rubber
sleeve's from housing.
8.Release clips and remove fuse box cover.
9.Remove nut securing ECM housing.
10.Release housing from retaining brackets and
remove.
M80 0557

HEATING AND VENTILATION
REPAIRS 80-13
21.Disconnect 3 Lucar connections from PTC
element.
22.Release cable ties securing PTC harness to
main harness.
23.Remove air intake plenum.

+ HEATING AND VENTILATION,
REPAIRS, Plenum - air intake.
24.Release 2 clips securing PTC harness from
plenum box section.
25.With assistance release 2 grommets from
bulkhead and remove PTC harness from
vehicle.Refit
1.With assistance route PTC harness through
bulkhead and fit grommets.
2.Fit clips securing PTC harness to plenum box
3.Fit air intake plenum.

+ HEATING AND VENTILATION,
REPAIRS, Plenum - air intake.
4.Fit cable ties securing PTC harness to main
bulkhead harness.
5.Connect Lucar connections to PTC element.
6.Fit air duct.
7.Fit RH demister vent duct.
8.Fit fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
9.Connect and secure PTC harness multiplug to
engine harness.
10.Secure PTC harness/relay to bulkhead bracket
11.Fit clip to secure PTC harness to ECM housing
bracket.
12.Fit PTC positive leads to (80 amp) fuse holder,
fit and tighten nuts to 7 Nm (5.2 lbf.ft).
13.Fit (80 amp) fuse cover.
14.Secure PTC harness/relays to ECM housing
bracket.
15.Fit fuse box, ensure harness routing is clear
suspension turret. Tighten nuts to 10 Nm (7
lbf.ft).
16.Fit fuse box cover.
17.Fit 'E' box housing into securing brackets.
18.Fit and tighten nut securing housing.
19.Fit harness and air duct rubber sleeve's to
housing.
20.Fit harness cable tie and secure relay in
housing.
21.Connect and secure joint harness and cooling
fan multiplugs.
22.Connect cooling fan sensor and gearbox ECU
multiplugs.
23.Fit ECM into 'E' box.

+ ENGINE MANAGEMENT SYSTEM -
EDC, REPAIRS, Engine control module
(ECM).
24.Position PTC positive cable to battery and
secure with bolt, tighten to 25 Nm (18 lbf.ft).
25.Connect battery earth lead.