2001 LAND ROVER FREELANDER air condition

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
03-19
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
03-20
Disciplines
Switch off the ignition prior to making any connection
or disconnection in the system, to prevent electrical
surges caused by disconnecting 'live' connections
damaging electronic components.
Ensure hands and work surfaces are clean and free
of grease, swarf, etc. Grease collects dirt which can
cause electrical tracking (short-circuits) or high-
resistance contacts.
When handling printed circuit boards, treat with care
and hold by the edges only; note that some electronic
components are susceptible to body static.
Connectors should never be subjected to forced
removal or refit, especially inter-board connectors.
Damaged contacts can cause short-circuit and
open-circuit fault conditions.
Prior to commencing test, and periodically during a
test, touch a good vehicle body earth to discharge
static charge. Some electronic components are
vulnerable to the static electricity that may be
generated by the operator.
Grease for electrical connectors
Some under bonnet and under body connectors may
be protected against corrosion by the application of a
special grease during vehicle production. Should
connectors be disturbed in service, or repaired or
replaced, additional grease should be re-applied:
Part No. BAU 5811, available in 150 gm tubs.
NOTE: The use of greases other than BAU 5811
must be avoided as they can migrate into relays,
switches etc. contaminating the contacts and leading
to intermittent operation or failure.
Supplementary restraint system
precautions
General
The Supplementary Restraint System (SRS)
provides active protection for vehicle occupants in
the event of a serious collision. The system
components include airbags and pre-tensioner seat
belts which are automatically deployed when a
severe frontal crash condition is detected.
The SRS pyrotechnic components could be
potentially hazardous to the service engineer if not
handled correctly. The following guidelines are
intended to alert the service engineer to potential
sources of danger and emphasise the importance of
ensuring the integrity of SRS components fitted to
the vehicle.
In order to assure system integrity, it is essential that
the SRS system is regularly checked and maintained
so that it is ready for operation in the event of an
accident.
Where necessary, additional specific precautions are
detailed in the relevant sections of this Manual which
should be referred to prior to commencing repair
operations.
WARNING: Always follow the 'SRS Precautions'
and the correct procedures for working on SRS
components. Persons working on SRS systems
must be fully trained and have been issued with
copies of the Safety guidelines.
WARNING: It is imperative that before any work
is undertaken on the SRS system the appropriate
information is read thoroughly.
WARNING: The airbag module contains sodium
azide which is poisonous and extremely
flammable. Contact with water, acid or heavy
metals may produce harmful or explosive
compounds. Do not dismantle, incinerate or
bring into contact with electricity, before the unit
has been deployed.
WARNING: Always replace a seat belt assembly
that has withstood the strain of a severe vehicle
impact, or if the webbing shows signs of fraying.
WARNING: Always disconnect the vehicle
battery before carrying out any electric welding
on a vehicle fitted with an SRS system.
CAUTION: Do not expose an airbag module or
seat belt pre-tensioner to heat exceeding 85º C
(185º F).

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.

GENERAL INFORMATION
03-28
SRS component replacement policy
The following information details the policy for
replacement of SRS components; either as a result
of a vehicle accident or as a result of vehicle age.
Impacts which do not deploy the airbags or seat
belt pre-tensioners
Check for structural damage in the area of the
impact, paying particular attention to bumper
armatures, longitudinals, crash cans and bracketry.
Impacts which deploy the airbags and/or seat
belt pre-tensioners
The inspection and replacement policy is dependent
on the type and severity of the crash condition. The
following guidelines are the minimum that should be
exercised as a result of the deployment of specific
SRS components.
Front airbag/ seat belt pre-tensioner deployment
(driver and passenger)
If the front airbags and/or seat belt pre-tensioners are
deployed as a result of a front, front angled or side
impact, the following parts must be replaced:
lDriver airbag module
lPassenger airbag module (where fitted)
lSRS flyleads
lSRS DCU
lRotary coupler
lFront seat belt pre-tensioners
In addition, the following should be inspected for
damage and replaced as necessary:
lFront seat belt and buckle tongue (anchorage
points, webbing etc.)
lFascia moulding adjacent to passenger airbag
module (where fitted)
lSteering wheel (if damage is evident)
lFront seat frames and head restraints (if there is
evidence of damage to the seat frame or
cushion pan)
lSteering column (if adjustment is lost or there
are signs of collapse)
lFront seat belt height adjusters on 'BC' posts (5
door models only)
lRear seat belts and seat belt buckles (webbing,
buckle covers, body anchorage and tongue
latching function)Rear Impact
If the seat belt pre-tensioners are deployed during a
rear impact, the following components must be
replaced:
lSeat belt pre-tensioners
lFront and rear automatic seat belt assemblies
used during an impact.
lSRS DCU
In addition, the following components should be
inspected for damage and replaced as necessary:
lFront seat frames
lFront seat belts and buckle (retractors,
webbing, tongue latching, buckle covers, body
anchorages and 'D' loops)
lSeat belt height adjusters (5 door models only)
lRear seat belts and seat belt buckles (webbing,
buckle covers, body anchorage and tongue
latching function)
Periodic replacement of SRS components
The performance of the propellants within airbags
and seat belt pre-tensioners will deteriorate over a
period of time. As a result, it is essential that the
airbags and seat belt pre-tensioners are periodically
replaced to maintain occupant safety. Airbags, seat
belt pre-tensioners and the rotary coupler should be
replaced at the recommended intervals.

GENERAL INFORMATION
03-29
Air conditioning system precautions
General
The air conditioning system contains fluids and
components which could be potentially hazardous to
the service engineer or the environment if not
serviced and handled correctly. The following
guidelines are intended to alert the service engineer
to potential sources of danger and emphasise the
importance of ensuring the integrity of the Air
Conditioning operating conditions and components
fitted to the vehicle.
Where necessary, additional specific precautions are
detailed in the relevant sections of this Manual which
should be referred to prior to commencing repair
operations.
The refrigerant used in the air conditioning system is
HFC-134a (Hydrofluorocarbon) R134a. Always
adhere to the following precautions:
WARNING: Servicing must only be carried out by
personnel familiar with both the vehicle system
and the charging and testing equipment. All
operations must be carried out in a well
ventilated area away from open flame and heat
sources.
WARNING: Do not allow a refrigerant container to
be heated by direct flame or to be placed near
any heating appliance. A refrigerant container
must not be heated above 50
°C.
Do not leave a container of refrigerant without its
cap fitted. Do not transport a container of
refrigerant that is unrestrained, especially in the
boot of a car.
WARNING: Do not smoke or weld in areas where
R134a is in use. Inhalation of concentrations of
vapour can cause dizziness, disorientation,
incoordination, narcosis, nausea or vomiting.
R134a is odourless and colourless. Do not
handle or discharge in an enclosed area, or any
area where the vapour and liquid can come in
contact with a naked flame or hot metal. R134a is
not flammable but can cause a highly toxic gas.
WARNING: Do not allow fluids other than R134a
or compressor lubricant to enter the air
conditioning system. Spontaneous combustion
may occur.WARNING: R134a is a hazardous liquid and when
handled incorrectly can cause serious injury.
Suitable protective clothing, consisting of face
protection, heat proof gloves, rubber boots and
rubber apron or waterproof overalls, must be
worn when carrying out operations on the air
conditioning system.
WARNING: Due to its low evaporating
temperature, R134a must be handled with care.
R134a splashed on any part of the body will
cause immediate freezing of that area. Also,
refrigerant cylinders and replenishment trolleys
when discharging will freeze skin to them if
contact is made.
WARNING: Under no circumstances should
refrigerant hoses be disconnected without first
discharging the system.
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.
WARNING: Refrigerant must always be recycled
before re-use to ensure that the purity of the
refrigerant is high enough for safe use in the air
conditioning system.
Recycling should always be carried out with
equipment which is design certified by
Underwriter Laboratory Inc. for compliance with
SAE J1991. Other equipment may not recycle
refrigerant to the required level of purity.
A R134a Refrigerant Recovery Recycling
Recharging Station must not be used with any
other type of refrigerant.
Refrigerant R134a from domestic and
commercial sources must not be used in motor
vehicle air conditioning systems.

GENERAL INFORMATION
03-30
Remedial actions
If an accident involving R134a should occur, conduct
the following remedial actions:
lIf liquid R134a enters the eye, do not rub it.
Gently run large quantities of eye wash over
affected eye to raise the temperature. If an eye
wash is not available, cool clean water may be
used to flush the eye. After rinsing, cover the
eye with a clean pad and seek immediate
medical attention.
lIf liquid R134a is splashed onto the skin, run
large quantities of water over the affected area
to raise the temperature. Implement the same
action if the skin comes in contact with
discharging cylinders. Wrap the contaminated
body parts in blankets (or similar materials) and
seek immediate medical attention.
lIf the debilitating effects of inhalation of R134a
vapour is suspected, seek fresh air. If the
affected person is unconscious, move them
away from the contaminated area to fresh air
and apply artificial respiration and/or oxygen
and seek immediate medical attention.
Service precautions
Observe the following precautions when handling
components used in the air conditioning system:
lAir conditioning units must not be lifted by their
hoses, pipes or capillary lines.
lHoses and lines must not be subjected to any
twist or stress - the efficiency of the system will
be impaired by kinks or restrictions. Ensure that
hoses are correctly positioned before tightening
couplings, and ensure that all clips and supports
are utilised.
lFlexible hoses should not be positioned close to
the exhaust manifold (less than 100mm) unless
protected by heat shielding.
lCompleted assemblies must be checked for
refrigeration lines touching metal panels. Any
direct contact of components and panels may
transmit noise and so must be eliminated.
lThe appropriate torque wrench must be used
when tightening refrigerant connections to the
stipulated value. An additional spanner must be
used to hold the union to prevent twisting of the
pipe when tightening connections.
lBefore connecting any hose or pipe, ensure that
refrigerant oil is applied to the seat of the new
'O' ring seals, BUT NOT to the threads of the
connection.
lAll protective plugs must remain in place to seal
the component until immediately prior to
connection.
lEnsure components are at room temperature
before uncapping, to prevent condensation of
moisture from the air that enters it.
lComponents must not remain uncapped for
longer than 15 minutes. In the event of a delay,
the caps must be fitted.
lWhen disconnecting, immediately cap all air
conditioning pipes to prevent ingress of dirt and
moisture into the system.
lThe modulator (receiver/drier) contains
desiccant which absorbs moisture. It must be
positively sealed at all times. A modulator that
has been left uncapped must not be used, fit a
new unit.
lThe modulator should be the last component
connected to the system to ensure optimum
dehydration and maximum moisture protection
of the system.
lWhenever the refrigerant system is opened, the
modulator must be renewed immediately before
evacuating and recharging the system.
lUse alcohol and a clean lint-free cloth to clean
dirty connections.
lEnsure that all new parts fitted are marked for
use with R134a.

GENERAL INFORMATION
03-31
When a major repair has been completed, a leak test
should be conducted; refer to the air conditioning
section of this manual for the correct procedure.
Refrigerant oil
Use an approved refrigerant lubricating oil:
ND Oil 8
CAUTION: Do not use any other type of
refrigerant oil.
CAUTION: Refrigerant oil easily absorbs water
and must not be stored for long periods. Do not
pour unused oil back into the container.
When renewing system components, add the
quantities of refrigerant oil recommended in the Air
Conditioning section of this manual.
Compressor
A new compressor is sealed and pressurised with
Nitrogen gas. When fitting a new compressor, slowly
release the sealing cap; gas pressure should be
heard to vent as the seal is broken.
CAUTION: A new compressor should always be
sealed and could be pressurised with nitrogen
gas. To avoid possible oil loss, release the
sealing cap(s) slowly. Do not remove the cap(s)
until immediately prior to connecting the air
conditioning pipes to the compressor.
Rapid refrigerant discharge
If the air conditioning system is involved in accident
damage and the system is punctured, the refrigerant
will discharge rapidly. The rapid discharge of
refrigerant will also result in the loss of most of the
oil from the system. The compressor must be
removed and all the remaining oil in the compressor
drained and refilled in accordance with the 'Air
Conditioning Compressor Replacement Procedure'.
Air conditioning compressor
replacement
A new compressor is supplied filled with a full charge
of (X cm3) of refrigerant oil.
A new compressor is supplied with an oil fill (X cm) of
120 cm
3.
A calculated quantity of oil must be drained from the
new compressor before fitting. To calculate the
quantity of oil to be drained:
1Remove the drain plug from the old
compressor.
2Invert the compressor and gravity drain the oil
into a calibrated measuring cylinder. Rotate the
compressor clutch to ensure the compressor is
completely drained.
3Note the quantity of oil drained (Y cm
3).
4Calculate the quantity of oil to be drained from
the new compressor using the following
formula:
X cm
3 – (Y cm3 + 20 cm3) = Q cm3
5Remove the drain plug from the new
compressor and drain Q cm3 of oil.
6Fit and tighten the compressor drain plug.
System components
When renewing system components, add the
following quantities of refrigerant oil:
lCondenser = 40 cm
3
lEvaporator = 30 cm 3
lReceiver drier = 15 cm 3
lPipe or hose = 5 cm 3