2001 LAND ROVER FREELANDER ECU

GENERAL INFORMATION
03-14
Self-locking nuts
Self-locking nuts, i.e. nylon insert or deferred thread
nuts can be re-used providing resistance can be felt
when the locking portion of the nut passes over the
thread of the bolt or stud.
DO NOT apply heat in an attempt to free deferred
thread nuts or fittings; as well as causing damage to
protective coatings, there is a risk of damage to
electronic equipment and brake linings from stray
heat.
Where self-locking nuts have been removed, it is
advisable to replace them with new ones of the same
type.
Where bearing pre-load is involved, nuts should be
tightened in accordance with special instructions.
Flexible pipes and hoses
General
When removing and installing flexible hydraulic pipes
and hoses, ensure that the following practices are
observed to ensure component serviceability:
lBefore removing any brake or power steering
hose, clean end fittings and area surrounding
them as thoroughly as possible.
lObtain appropriate plugs or caps before
detaching hose end fittings, so that the ports
can be immediately covered to prevent the
ingress of dirt.
lClean hose externally and blow through with
airline. Examine carefully for cracks, separation
of plies, security of end fittings and external
damage. Reject any faulty hoses.
lWhen refitting a hose, ensure that no
unnecessary bends are introduced, and that
hose is not twisted before or during tightening of
union nuts.
lFit a cap to seal a hydraulic union and a plug to
its socket after removal to prevent ingress of
dirt.
lAbsolute cleanliness must be observed with
hydraulic components at all times.
lAfter any work on hydraulic systems, carefully
inspect for leaks underneath the vehicle while a
second operator applies maximum brake
pressure to the brakes (engine running) and
operates the steering.
Do not disconnect any pipes in an air
conditioning refrigeration system unless trained
and instructed to do so. A refrigerant is used
which can cause blindness if allowed to contact
eyes.

GENERAL INFORMATION
03-16
'Oetiker' clips may be removed by bending the tag
(arrowed) and releasing the free end of the clip. Clips
must not be re-used. When fitting new clips, ensure
the clip is correctly positioned on the hose before
tightening and that when the clip is tightened, the tag
is located in the longitudinal slot in the free end of the
clip (arrowed in illustration).
Heat protection
Always ensure that heatshields and protective
sheathing are in good condition. Replace if damage
is evident.
Particular care must be taken when routing hoses
close to hot engine components, such as the exhaust
manifold and the Exhaust Gas Recirculation (EGR)
pipe.
Hoses will relax and deflect slightly when hot; ensure
this movement is taken into account when routing
and securing hoses.
Service tools
General
Special service tools have been developed to
facilitate removal, dismantling and assembly of
mechanical components in a cost effective and time
efficient manner. The use of such special tools also
helps prevent the potential for damage to
components.
Some operations described in this Manual cannot be
carried out properly without the aid of the relevant
service tools.
All orders and enquiries from the United Kingdom
and European countries except Germany, Austria,
Switzerland and Spain and countries not in the
following list should be sent direct to:
SPX UK Ltd.,
Genoa House,
Everdon Park,
Daventry,
Northants,
NN11 5YJ
England
( 00 44 (0) 132 7303467/303455
) 00 44 (0) 1327 706632
e-mail: [email protected]
Overseas orders for the following countries should
be placed with the local SPX distributor.
Germany, Austria and Switzerland
SPX Europe GMBH,
Porschestrasse 4,
63512 Hainburg,
Germany
( 0049 61829590
) 0049 6182959299
Spain
SPX Iberica SA,
C/Francisco Aritio
158 nave 72 (Nudo Oeste),
19004 Guadalajara,
Spain
( 0034 949208381
) 0034 949208327
North America

GENERAL INFORMATION
03-18
Fuel handling precautions
Fuel vapour is highly inflammable and in confined
spaces is also explosive and toxic. The vapour is
heavier than air and will always fall to the lowest
level. The vapour can easily be distributed
throughout a workshop by air currents;
consequently, even a small spillage of fuel is
potentially very dangerous.
The following information provides basic precautions
which must be observed if petrol (gasoline) is to be
handled safely. It also outlines other areas of risk
which must not be ignored. This information is issued
for basic guidance only, if in doubt consult your local
Fire Officer.
General
Always have a fire extinguisher containing FOAM,
CO
2, GAS or POWDER close at hand when handling
or draining fuel or when dismantling fuel systems.
Fire extinguishers should also be located in areas
where fuel containers are stored.
Always disconnect the vehicle battery before
carrying out dismantling or draining work on a fuel
system.
Whenever fuel is being handled, drained or stored, or
when fuel systems are being dismantled, all forms of
ignition must be extinguished or removed; any
leadlamps must be flameproof and kept clear of
spillage.
WARNING: No one should be permitted to repair
components associated with fuel without first
having specialist training.
WARNING: Do not remove fuel system
components while the vehicle is over a pit.Fuel tank draining
Fuel tank draining should be carried out in
accordance with the procedure outlined in the FUEL
DELIVERY section of this manual and observing the
following precautions:
WARNING: Fuel must not be extracted or drained
from any vehicle while it is over a pit. Extraction
or draining of fuel must be carried out in a well
ventilated area.
The capacity of containers must be more than
adequate for the amount of fuel to be extracted or
drained. The container should be clearly marked
with its contents and placed in a safe storage
area which meets the requirements of local
authority regulations.
WARNING: When fuel has been drained from a
fuel tank the precautions governing naked lights
and ignition sources should be maintained.
Fuel tank removal
When the fuel line is secured to the fuel tank outlet by
a spring steel clip, the clip must be released before
the fuel line is disconnected or the fuel tank is
removed. This procedure will avoid the possibility of
residual petrol fumes in the fuel tank being ignited
when the clip is released.
As an added precaution, fuel tanks should have a
'FUEL VAPOUR' warning label attached to them as
soon as they are removed from the vehicle.
Fuel tank repairs
No attempt should be made to repair a plastic fuel
tank. If the structure of the tank is damaged, a new
tank must be fitted.
Body repairs
Plastic fuel pipes are particularly susceptible to heat,
even at relatively low temperature, and can be
melted by heat conducted from some distance away.
When body repairs involve the use of heat, all fuel
pipes which run in the vicinity of the repair area must
be removed, and the tank outlet plugged.

GENERAL INFORMATION
03-19
Electrical precautions
General
The following guidelines are intended to ensure the
safety of the operator and ensure the prevention of
damage to the electrical and electronic components
fitted to the vehicle. Where necessary, specific
precautions are detailed in the individual procedures
of this manual.
Equipment
Prior to commencing any test procedure on the
vehicle, ensure that the relevant test equipment is
working correctly and any harness or connectors are
in good condition. It is particularly important to check
the condition of the lead and plugs of mains operated
equipment.
Polarity
Never reverse connect the vehicle battery and
always ensure the correct polarity when connecting
test equipment.
High Voltage Circuits
Whenever disconnecting live ht circuits, always use
insulated pliers and never allow the open end of the
ht lead to contact other components, particularly
ECU's.
Exercise caution when measuring the voltage on the
coil terminals while the engine is running, high
voltage spikes can occur on these terminals.
Connectors and harnesses
The engine compartment of a vehicle is a particularly
hostile environment for electrical components and
connectors:
lAlways ensure electrically related items are dry
and oil free before disconnecting and
connecting test equipment.
lEnsure disconnected multiplugs and sensors
are protected from being contaminated with oil,
coolant or other solutions. Contamination could
impair performance or result in catastrophic
failure.
lNever force connectors apart using tools to
prise apart or by pulling on the wiring harness.
lAlways ensure locking tabs are disengaged
before disconnection, and match orientation to
enable correct reconnection.
lEnsure that any protection (covers, insulation
etc.) is replaced if disturbed.Having confirmed a component to be faulty:
lSwitch off the ignition and disconnect the
battery.
lRemove the component and support the
disconnected harness.
lWhen replacing the component, keep oily hands
away from electrical connection areas and push
connectors home until any locking tabs fully
engage.
Battery disconnection
Before disconnecting the battery, disable the alarm
system and switch off all electrical equipment. If the
radio is to be serviced, ensure the security code has
been deactivated.
CAUTION: To prevent damage to electrical
components, always disconnect the battery
when working on the vehicle's electrical system.
The ground lead must be disconnected first and
reconnected last.
CAUTION: Always ensure that battery leads are
routed correctly and are not close to any
potential chafing points.
Battery charging
Only recharge the battery with it removed from the
vehicle. Always ensure any battery charging area is
well ventilated and that every precaution is taken to
avoid naked flames and sparks.
Ignition system safety precautions
The vehicle's ignition system produces high voltages
and the following precautions should be observed
before carrying out any work on the system:
WARNING: Before commencing work on an
ignition system, ensure all high tension
terminals, adapters and diagnostic equipment
are adequately insulated and shielded to prevent
accidental personal contacts and minimise the
risk of shock. Wearers of surgically implanted
pacemaker devices should not be in close
proximity of ignition circuits or diagnostic
equipment.

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
03-24
SRS Harnesses and Connectors

CAUTION: Always observe the following
precautions with regards to SRS system
electrical wiring:
lNever attempt to modify, splice or repair
SRS wiring.
lNever install electronic equipment (such as
a mobile telephone, two-way radio or in-car
entertainment system) in such a way that it
could generate electrical interference in the
airbag harness. Seek specialist advice when
installing such equipment.
NOTE: SRS system wiring can be identified by a
special yellow outer sleeve protecting the wires
(black with yellow stripe protective coverings are
sometimes used).
WARNING: Always ensure SRS wiring is routed
correctly. Be careful to avoid trapping or
pinching the SRS wiring. Do not leave the
connectors hanging loose or allow SRS
components to hang from their harnesses. Look
for possible points of chafing.CAUTION: Ensure all SRS harness connectors
are mated correctly and securely fastened. Do
not leave the connectors hanging loose.
Rotary Coupler

CAUTION: Always follow the procedure for fitting
and checking the rotary coupler as instructed in
the SRS repairs section. Comply with all safety
and installation procedures to ensure the system
functions correctly. Observe the following
precautions:
lDo not install a rotary coupler if it is
suspected to be defective.
lDo not attempt to service, modify or repair a
rotary coupler.
lDo not cut, splice or modify the wires
attached to the rotary coupler.
lAlways ensure the rotary coupler
connectors are mated correctly and securely
fastened.
lAlways ensure the battery is disconnected
before working on the rotary coupler.
lDo not unlock and rotate the rotary coupler
when it is removed from the vehicle.
lDo not turn the road wheels when the rotary
coupler is removed from the vehicle.
lAlways ensure the rotary coupler is removed
and installed in its centred position and with
the front road wheels in the straight ahead
position - refer to the SRS repair section for
the correct removal and installation
procedure.
lIf a new rotary coupler is being installed,
ensure the locking tab holding the coupler's
rotational position is not broken; units with a
broken locking tab should not be used.

GENERAL INFORMATION
03-27
SRS component manual deployment
If a vehicle is to be scrapped and contains an
undeployed airbag module, the module must be
manually deployed. Always observe the following
precautions:
WARNING: Only personnel who have undergone
the appropriate training should undertake
deployment of airbag and seat belt pre-tensioner
modules.
WARNING: A deployed airbag or seatbelt pre-
tensioner is very hot, DO NOT return to a
deployed airbag module until at least 30 minutes
have elapsed since deployment.
WARNING: Only use approved deployment
equipment, and only deploy SRS components in
a well ventilated designated area. Ensure SRS
components are not damaged or ruptured before
deployment. Notify the relevant authorities.
WARNING: If a vehicle is to be scrapped,
undeployed airbag modules and pre-tensioner
units must be deployed in accordance with the
instructions in this manual.
WARNING: Contact with chemicals from
deployed and damaged SRS components could
present a health hazard, wear protective clothing
when handling. DO NOT eat, drink or smoke
when handling SRS components.
WARNING: Deployment of airbag modules and
seatbelt pre-tensioners can cause injury to
personnel in the close vicinity of the deploying
unit. In case of injury seek urgent medical advice.
Possible sources of injury include:
limpact - due to inflating airbag or pre-
tensioner operation causing component
'kick'.
l hearing - due to noise produced by
deploying airbags and seatbelt pre-
tensioner units.
l burns - hot component parts and gases.
l irritation to eyes and lungs - from deploying
gases or combustion residue.
WARNING: Ensure the SRS component to be
deployed is securely fastened to its mounting.WARNING: Deployment procedures detailed in
this manual should be strictly adhered to.
Compliance with the following precautions
MUST be ensured:
lOnly use deployment equipment approved
for the intended purpose.
lBefore commencing deployment procedure,
ensure the deployment tool functions
properly by performing the self test
procedure detailed in the SRS Repairs
section of this manual.
lDeployment of airbag/pre-tensioner
modules should be performed in a well
ventilated area which has been designated
for the purpose.
lEnsure airbag/pre-tensioner modules are
not damaged or ruptured before attempting
to deploy.
lNotify the relevant authorities of intention to
deploy airbag and pre-tensioner units.
lWhen deploying airbag and seatbelt pre-
tensioner units, ensure that all personnel are
at least 15 metres away from the deployment
zone.
lEnsure deployment tool is connected
correctly, in compliance with the
instructions detailed in this manual. In
particular, ensure deployment tool is NOT
connected to battery supply before
connecting to the airbag or seatbelt pre-
tensioner module connector.
lWhen deploying seatbelt pre-tensioners in
the vehicle, ensure the pre-tensioner unit is
fully secured to its fixing point.
lWhen removing deployed airbag and
seatbelt pre-tensioner modules, wear
protective clothing. Use gloves and seal
deployed units in a plastic bag.
lFollowing deployment of any component of
the SRS system within the vehicle, all SRS
components must be replaced. DO NOT re-
use or salvage any parts of the SRS system.
lDo not lean over airbag modules or seatbelt
pre-tensioner units when connecting
deployment equipment.
WARNING: During deployment parts of the
airbag module become hot enough to burn you.
Wait 30 minutes after deployment before
touching the airbag module.

TORQUE WRENCH SETTINGS
06-28
Brakes
1 Use NEW bolts
TORQUE DESCRIPTION METRIC IMPERIAL
ABS ECU pipe unions 17 Nm 12 lbf.ft
ABS modulator to mounting bracket bolts 9 Nm 7 lbf.ft
ABS modulator mounting bracket to inner wing:
⇒ Nuts
⇒ Bolts13 Nm
8 Nm10 lbf.ft
6 lbf.ft
Bleed screw - front calipers 10 Nm 7.5 lbf.ft
Brake servo to bulkhead nuts 22 Nm 16 lbf.ft
EGR cooler to mounting bolts 25 Nm 18 lbf.ft
EGR pipe support bracket to engine lifting bracket bolts 25 Nm 18 lbf.ft
Front caliper brake hose banjo bolt 28 Nm 21 lbf.ft
Front caliper guide pin bolts 27 Nm 20 lbf.ft
Front caliper mounting bolts 100 Nm 74 lbf.ft
Front disc shield to hub screw 8.5 Nm 6.3 lbf.ft
Front disc to drive flange screws 5 Nm 3.7 lbf.ft
Fuel rail to support bracket bolt 10 Nm 7.5 lbf.ft
Handbrake cable to body and subframe bolts 22 Nm 16 lbf.ft
Handbrake cable retaining plate bolts 22 Nm 16 lbf.ft
Handbrake lever assembly to body bolts 22 Nm 16 lbf.ft
Hill Descent Control (HDC) switch bolt 5 Nm 3.5 lbf.ft
Master cylinder to servo nuts 25 Nm 18 lbf.ft
PAS oil cooler pipe bolts 10 Nm 7.5 lbf.ft
Primary and secondary brake pipe union nuts 17 Nm 12 lbf.ft
Rear wheel cylinder pipe union nut 17 Nm 12 lbf.ft
Rear wheel cylinder to backplate bolts 8 Nm 6 lbf.ft
Reservoir to master cylinder (LHD) Torx bolt 8 Nm 6 lbf.ft
Reservoir to master cylinder (LHD) Torx bolt 6 Nm 4.5 lbf.ft
Road wheel nuts 115 Nm 85 lbf.ft
Turbocharger intercooler pipe to support bracket bolt 10 Nm 7.5 lbf.ft
Turbocharger pipe to coolant rail bolt 25 Nm 18 lbf.ft
Vacuum pump bolts
122 Nm 16 lbf.ft
Vacuum reservoir to mounting bracket nut 10 Nm 7.5 lbf.ft