2001 LAND ROVER FREELANDER suspension

MAINTENANCE
MAINTENANCE 10-27
Suspension
Check Front Suspension
1.Check condition of all ball joint dust covers,
including anti-roll bar links.
2.Check tightness of all accessible suspension
fixings including tie rods.
3.Check wheel bearings and suspension struts
for signs of excessive play or wear.
4.Check track rod ends for wear by attempting to
move the joint forwards and backwards, side to
side and up and down. No wear should be
apparent, if any is detected then the joint must
be replaced.
5.Check for signs of leakage from suspension
dampers.Check Rear Suspension
1.Check tightness of all accessible suspension
fixings including transverse links.
2.Check wheel bearings and suspension struts
for signs of excessive play or wear.
3.Check for signs of leakage from suspension
dampers.
Check Tow Bar Fixings
1.Check that the two vertical fixings are tightened
to a torque of 110 Nm (82 lbf.ft).
2.Check that the six transverse fixings are
tightened to a torque of 60 Nm (45 lbf.ft).

MAINTENANCE
MAINTENANCE 10-29
Gear Change and Parking Pawl Engagement –
(Automatic only, normal driving conditions)
1.Select 'R' and check for smooth take up.
2.Select 'D' and check for smooth up-changes of
ratio from rest.
3.Slow down vehicle and check for smooth down-
changes of ratio.
4.Stop vehicle on a slope.
5.Select 'P' and release handbrake.
6.Check that vehicle does not move and that
selector does not slip out of 'P'.
7.Carry out a similar check with vehicle facing in
the opposite direction.
Steering
1.With vehicle stationary, turn steering from lock
to lock. Check for smooth operation and ensure
there is no undue noise from the power steering
pump or drive belt.
Suspension
1.Check for noise, irregularity in ride (e.g.
dampers) and wheel imbalance.
Foot brake
1.Check for pedal effort, travel, braking
efficiency, pulling and binding.
Handbrake
1.Apply handbrake firmly, check travel and
ratchet hold and release.
Instruments
1.Check for correct operation of all instruments
and warning devices where practical.
Body
1.Check for abnormal body noise.
Seat Belts
1.Check for operation of inertia reels.Road Test
1.Drive vehicle on a short road test. Check all
vehicle systems for correct operation. Pay
particular attention to:
lEngine noise
lGearbox noise
lSuspension noise
lBody noise
lBraking system operation
lGear selection
lEngine performance
2.Where possible, check for correct operation of
Hill Descent Control (HDC) system. This should
not be carried out if excessive journey time is
required.
3.After road test, carry out a final inspection of the
vehicle on vehicle ramps.
4.Check all underbonnet fluid levels and top-up if
necessary.

ENGINE - K SERIES KV6
REPAIRS 12-3-29
33.With an assistant depressing the brake pedal,
remove and discard LH and RH drive shaft
nuts.
34.Remove rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
35.Remove exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - Non
NAS.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - NAS.
36.Raise one rear wheel for rotation of propeller
shaft to access bolts.
37.Reference mark position of viscous coupling
flange to IRD unit flange to aid reassembly.
38.Remove 6 nuts and bolts securing propeller
shaft to IRD drive flange.
39.Release propeller shaft from IRD drive flange
and tie shaft aside.
CAUTION: Care must be taken to support
the Tripode joint when removed from the
IRD unit. To avoid damage to gaiter or steel
can, the joint should not be allowed to fully
extend or be dropped.40.Drain gearbox fluid.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
41.Drain fluid from IRD.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
42.Remove 6 bolts securing RH and LH front
splash shields and remove shields.
43.Remove clips securing brake hoses to RH and
LH damper brackets.
44.Release ABS sensor leads from bracket.
45.Release ABS sensors from RH and LH front
hubs.
M12 6614

ENGINE - K SERIES KV6
REPAIRS 12-3-33
71.Remove 3 bolts securing PAS pump to front
mounting plate and tie pump aside.
72.With assistance, manoeuvre and lower engine
and gearbox to floor.
Refit
1.With assistance, raise engine and gearbox into
engine compartment.
2.Position PAS pump to front mounting plate, fit
and tighten bolts to 25 Nm (18 lbf.ft).
3.Position PAS pump pulley, fit and tighten Torx
screws to 9 Nm (7 lbf.ft).
4.Position top arm to engine mounting bracket
and RH hydramount, fit and tighten bolts to 100
Nm (74 lbf.ft).
5.Position PAS pipe support bracket to RH
hydramount, fit and tighten nut to 85 Nm (63
lbf.ft).
6.Place a wooden block on jack, position jack
under gearbox and raise jack sufficient to
support weight of gearbox. Release lifting hook
from lifting bracket on gearbox and connect to
rear engine lifting bracket.
7.Lower and remove jack supporting gearbox.
8.Remove bolts securing LRT-44-026 lifting
bracket to gearbox and remove bracket.
9.Position LH mounting bracket to gearbox, fit
and tighten bolts to 85 Nm (63 lbf.ft).
10.Position LH mounting to body, fit and tighten
bolts to 48 Nm.
11.Align gearbox bracket to LH body mounting, fit
and tighten through bolt to 100 Nm (74 lbf.ft).
12.Position upper RH engine steady to top arm, fit
and tighten bolt to 100 Nm (74 lbf.ft).
13.Tighten bolt securing upper RH engine steady
to body to 100 Nm (74 lbf.ft).
14.Position PAS pipe to engine front mounting
plate, fit and tighten bolt to 25 Nm (18 lbf.ft).
15.Lower hoist, disconnect and remove lifting
bracket, LRT-12-138.
16.Raise vehicle on ramp.17.Position A/C compressor to front mounting
plate and cylinder block, align heat shield, fit
and tighten bolts to 25 Nm (18 lbf.ft).
18.Connect multiplug to A/C compressor.
19.Using a 3/8 square drive socket bar, raise
ancillary drive belt tensioner and fit drive belt to
pulleys.
20.Position selector cable to gearbox bracket and
secure with clip.
21.Position selector lever to selector shaft, fit and
tighten nut to 25 Nm (18 lbf.ft).
22.Clean splines and seal areas on each
driveshaft and mating faces in front hubs.
23.Fit new circlips to RH and LH driveshaft inner
joint splines.
24.Fit driveshafts to IRD and gearbox, ensuring
that the circlip on each driveshaft is fully
engaged.
25.Engage LH and RH driveshafts into front hubs.
26.Fit new driveshaft flange nuts but do not tighten
at this stage.
27.Clean ball joint tapers and taper seats.
28.Position LH and RH track rod ends to steering
arms, fit new nuts and tighten to 55 Nm (40
lbf.ft).
29.Clean ABS sensors and mating faces.
30.Apply anti-seize grease to both ABS sensors
and position sensors in front hubs.
Ensure ABS sensor is fully located into hub,
so that sensor touches pole wheel teeth.
31.Position LH and RH brake hoses to front
damper brackets and secure with clips.
32.Position LH and RH splash shields, fit and
tighten bolts.
33.Ensure mating face of propeller shaft and IRD
drive flange are clean.
34.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 42 Nm (31
lbf.ft).
35.Fit rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
36.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
37.Fit exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - Non
NAS.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - NAS.

ENGINE - K SERIES KV6
REPAIRS 12-3-39
37.Raise vehicle on lift.
38.Remove front road wheels.
39.Release stake in drive shaft nuts.
40.With assistant depressing the brake pedal,
remove and discard LH and RH drive shaft
nuts.
41.Remove rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
42.Remove exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - NAS.
43.Raise one rear wheel for rotation of propeller
shaft to access bolts.
44.Reference mark position of viscous coupling
flange to IRD unit flange to aid reassembly.
45.Remove 6 nuts and bolts securing propeller
shaft to IRD drive flange.
46.Release propeller shaft from IRD drive flange
and tie shaft aside.
CAUTION: Care must be taken to support
the Tripode joint when removed from the
IRD unit. To avoid damage to gaiter or steel
can, the joint should not be allowed to fully
extend or be dropped.47.Drain gearbox fluid.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
48.Drain fluid from IRD.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
49.Remove 6 bolts securing RH and LH front
splash shields and remove shields.
50.Remove clips securing brake hoses to RH and
LH damper brackets.
51.Release ABS sensor leads from bracket.
52.Release ABS sensors from RH and LH front
hubs.
M12 6614

ENGINE - K SERIES KV6
12-3-44 REPAIRS
35.Fit rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
36.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
37.Fit exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - NAS.
38.With assistant depressing the brake pedal,
tighten front hub nuts to 400 Nm.
39.Stake nuts to drive shafts
40.Fit front road wheels, fit and tighten nuts to 115
Nm.
41.Lower vehicle on lift.
42.Connect brake servo vacuum hose to inlet
manifold chamber.
43.Connect coolant hose to underside of
expansion tank and secure with clip.
44.Connect expansion tank hose to inlet manifold
and secure clip.
45.Connect top hose to radiator and secure with
clip. Position hose in bracket.
46.Connect heater feed and return hoses and
secure with clips.
47.Connect throttle inner cable to throttle cam and
secure outer cable in abutment bracket.
48.Connect hose to purge valve.
49.Fit purge hose into clip.
50.Connect fuel hose to fuel rail pipe, fit rubber
sleeve over hose connector.
51.Connect gearbox harness multiplugs and
secure multiplugs in mounting bracket clips.
52.Connect Lucar connector to starter solenoid.
53.Position earth lead to gearbox housing, fit and
tighten bolt to 25 Nm.
54.Position engine harness to 'E' box mounting
bracket and secure with clips.
55.Connect earth header multiplug.
56.Connect multiplug to under bonnet fuse box.
57.Position battery and starter motor lead to under
bonnet fuse box, fit and tighten bolts to 8 Nm.
58.Fit under bonnet fuse box cover.
59.Position 'E' box, secure in retaining clip, fit and
tighten nut to 9 Nm.
60.Fit carrier to 'E' box.
61.Fit air ducting to 'E' box.
62.Fit body harness to 'E' box, secure grommet
and harness clip.
63.Connect 'E' box cooling fan multiplug.
64.Connect multiplug to 'E' box temperature
sensor.
65.Connect multiplug to gearbox ECU.
66.Position engine harness to 'E' box and secure
grommet.67.Fit engine harness clamp and secure with
screws.
68.Connect engine harness multiplug to body
harness multiplug and fit multiplug to 'E' box.
69.Fit heated front screen harness to battery
positive cable and tighten bolt to 15 Nm (11
lbf.ft).
70.Fit engine ECM.

+ ENGINE MANAGEMENT SYSTEM -
SIEMENS, REPAIRS, Engine control module
(ECM) - fuel - NAS.
71.Fit battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
72.Fill cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
73.Connect the battery earth lead.
74.Fill gearbox with fluid.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
75.Fit the engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
76.Untie and close bonnet.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-3
REPAIRS
Intermediate reduction drive (IRD) unit -
Td4
$% 41.25.01.99
Remove
1.Disconnect battery earth lead.
2.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
3.Remove rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
4.Remove exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - front.
5.Drain fluid from IRD.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
6.Drain gearbox fluid.

+ MANUAL GEARBOX - GETRAG,
ADJUSTMENTS, Gearbox oil - drain and
refill.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
7.Remove 3 bolts securing RH splash shield to
body and remove shield.8.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release drive shaft from
IRD.
9.With assistance, pull hub outwards and release
drive shaft from IRD.
10.Remove and discard drive shaft circlip.
11.Reference mark front propeller shaft for
reassembly.
12.Raise one rear wheel for rotation of propeller
shaft to access bolts.

INTERMEDIATE REDUCTION DRIVE
41-6 REPAIRS
Refit
1.Clean mating faces of IRD and gearbox.
2.Lubricate and fit new 'O' ring
3.With assistance, fit IRD.
4.Fit bolts securing IRD to gearbox and tighten
sufficiently only to pull mating faces of IRD and
gearbox together at this stage.
5.Fit IRD support brackets, tighten sufficiently to
pull mating faces together.
6.Final tighten bolts securing IRD to gearbox to
90 Nm (66 lbf.ft).
7.Final tighten bolts securing IRD support
brackets in the following sequence:
lM8 bolts securing support brackets to IRD
37 Nm (22 lbf.ft)
lM10 bolts securing support brackets to IRD
50 Nm (22 lbf.ft)
l3 bolts securing support bracket to cylinder
block 25 Nm (18 lbf.ft)
l3 bolts securing support bracket to sump at
45 Nm (33 lbf.ft).
8.Position lower engine steady, 'TOP' mark
uppermost. Fit bolt but do not tighten at this
stage.
9.Connect coolant hoses and secure with clips.
10.Connect breather hose to IRD housing.
11.Clean propeller shaft flange and mating face.
12.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 40 Nm (30
lbf.ft).
13.Inspect drive shaft oil seal, renew if worn or
damaged.14.Clean drive shaft and flange splines.
15.Fit new circlip to drive shaft.
16.With assistance, pull hub outwards, align drive
shaft and fit to IRD taking care not to damage
oil seal.
17.Fit splash shield and secure with bolts.
18.Fit exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - front.
19.Fit rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
20.Final tighten bolt securing lower engine steady
to IRD support bracket to 100 Nm (74 lbf.ft).
21.Remove stand(s) and lower vehicle.
22.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
23.Fill gearbox with fluid.

+ MANUAL GEARBOX - GETRAG,
ADJUSTMENTS, Gearbox oil - drain and
refill.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
24.Connect battery earth lead.
25.Refill cooling system.

+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.