2001 LAND ROVER FREELANDER Workshop Manual

STEERING
57-4 ADJUSTMENTS
Power steering - pressure test
$% 57.90.10.01
Check
1.Position absorbent cloth to catch spillage.
2.Remove bolt securing PAS high pressure pipe
clip to PAS pump.
3.Loosen union securing high pressure pipe to
PAS pump and release pipe.
4. K1.8 models: Fit adaptor LRT-57-034A to high
pressure port of PAS pump.
5. KV6 & Td4 models: Fit adaptor LRT-57-042 to
high pressure port of PAS pump.
6.Fit adaptor LRT-57-035 to existing high
pressure hose.
7.Fit hose LRT-57-002 to each adaptor.
8.Fit pressure gauge LRT-57-005 to test valve
LRT-57-001
9.Connect hoses LRT-57-002 to LRT-57-001
and tighten unions.
10.Ensure steering system and test equipment is
free from leaks.
11.Maintain maximum fluid level during test.
12.With the test valve open, start the engine.
13.Pressure at idle should be between 5 and 7
bar.
14.With the engine at idle, slowly turn the steering
wheel and hold on full lock.
15.Repeat procedure for other side.
16.Test pressure should rise significantly as
steering wheel is rotated and continue to rise as
full lock is approached. For full lock pressures,
refer to general data section.

+ GENERAL DATA, Steering.
17.With the engine at idle, release steering wheel.
For idle pressure, refer to general data section.

+ GENERAL DATA, Steering.
18.Pressures outside the above tolerance
indicates a fault.19.To determine if fault is in steering pump or
steering rack, close the test valve for a
maximum of 5 seconds.
CAUTION: Pump damage will occur if test
valve is closed for longer periods.
20.If gauge does not register correct reading,
suspect faulty pump.
21.If PAS pump pressure is correct and steering is
heavy at idle and becomes light as engine RPM
is increased, suspect pump flow rate.
22.If maximum pump pressure is correct, suspect
steering rack.
23.On completion stop engine and remove test
equipment.
24.Clean PAS pump and pipe union.
25.Fit new 'O' ring to high pressure pipe, align to
PAS pump and tighten union to 25 Nm (18
lbf.ft).
26.Fit bolt securing high pressure pipe clip and
tighten to 8 Nm (6 lbf.ft).
27.Check and top-up PAS fluid level.

+ MAINTENANCE, MAINTENANCE,
Intermediate Reduction Drive - Non NAS
models.

STEERING
REPAIRS 57-5
REPAIRS
Power steering rack
$% 57.10.01
Remove
1.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.
2.Remove front road wheels.
3.Remove and discard nuts securing track rod
ball joints to steering arms.
4.Fit an M12 nut to each ball pin, flush with end of
each pin.
5.Using LRT-57-043, separate ball pins from RH
and LH steering arms. Remove M12 nuts and
release ball pins from steering arms.
6.Remove pinch bolt securing steering column to
PAS rack pinion.7. KV6 models: Remove 2 nuts securing steering
rack heat shield and remove heat shield.
8. KV6 models: Remove 2 bolts securing coolant
rail to cylinder block.
9. Td4 manual models: Using tool LRT-37-050
release gear change rods from gear change
linkage.
10. Td4 manual models: Remove 2 bolts securing
gearchange linkage to bulkhead and tie aside.

STEERING
57-6 REPAIRS
11. Td4 manual models: Remove bolt securing
IRD coolant hose 'P' clip.
12. Td4 auto models: Remove bolt securing IRD
coolant hose 'P' clip.
13.Remove 2 bolts and washers securing PAS
rack clamp to bulkhead, discard bolts.
14.Remove PAS rack clamp.
15.Remove rubber mount.16.Remove and discard 2 bolts securing PAS rack
mounting to bulkhead.
17.Release PAS rack pinion from steering column.
18.Position container to collect PAS fluid spillage.
19.Remove bolt securing pipe bracket to PAS
rack.
20.Release pipe unions and disconnect fluid pipes
from PAS rack.
CAUTION: Always fit plugs to open
connections to prevent contamination.
21.Remove and discard 'O' rings.
22.Remove bolt securing PAS pipes to clamp and
loosen clamp bolt.
23. KV6 models: Remove RH Hydramount and
lower engine to aid rack removal.

+ ENGINE - K SERIES KV6, REPAIRS,
Hydramount - engine - RH.
24.With assistance remove PAS rack from
passenger side of vehicle.

M57 1071

STEERING
REPAIRS 57-7
25.Remove dust seal from pinion housing.
Refit
1.Fit PAS rack to vehicle from passengers side.
2.Fit dust shield to pinion housing.
3. KV6 models: Fit RH Hydramount.

+ ENGINE - K SERIES KV6, REPAIRS,
Hydramount - engine - RH.
4.Ensure pipe unions are clean.
5.Fit new 'O' rings to fluid pipes.
6.Fit fluid pipes to PAS rack but do not tighten at
this stage.
7.Align fluid pipe bracket to PAS rack, fit bolt but
do not tighten at this stage.
8.With assistance fit PAS rack pinion to steering
column, ensuring column coupling is aligned
with gear input flag.
9.Fit washers and new bolts securing steering
rack mounting to bulkhead, but do not tighten at
this stage. Ensure large washer is fitted to lower
bolt.
10.Fit rubber mount and clamp to PAS rack.
11.Fit bolts securing clamp to bulkhead but do not
tighten at this stage.
12.Tighten PAS rack mounting bolts to 45 Nm (33
lbf.ft).
13.Tighten PAS rack clamp bolts to 45 Nm (33
lbf.ft).
14.Tighten PAS rack fluid feed pipe union to 18
Nm (13 lbf.ft).
15.Tighten PAS rack fluid return pipe union to 22
Nm (16 lbf.ft).
16.Tighten fluid pipe bracket to 10 Nm (7 lbf.ft).
17.Align PAS rack clamp and tighten bolt.
18.Align pipes to clamp fit bolt and tighten to 10
Nm (7 lbf.ft).
19.Fit pinch bolt to steering column and tighten to
32 Nm (24 lbf.ft).
CAUTION: Nuts and bolts must be tightened
with the weight of the vehicle on the
suspension.20.Ensure tapers in track rod end and steering arm
are clean and rubber boot is not damaged.
21.Fit ball joints to steering arms, fit new nuts and
tighten to 55 Nm (40 lbf.ft).
22. KV6 models: Align coolant rail to cylinder
block, fit bolts and tighten to 10 Nm (7 lbf.ft).
23. KV6 models: Position heat shield, fit nuts and
tighten to 25 Nm (18 lbf.ft)
24. Td4 manual models: Align IRD hose 'P' clip fit
bolt and tighten to 25 Nm (18 lbf.ft).
25. Td4 manual models: Align gearchange
linkage to bulkhead, fit bolts and tighten to 25
Nm (18 lbf.ft).
26. Td4 manual models: Connect gear change
rods to gear change linkage.
27. Td4 auto models:Align IRD hose 'P' clip fit bolt
and tighten to 25 Nm (18 lbf.ft).
28.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
29.Remove stands and lower vehicle.
30.Bleed PAS system.

+ STEERING, ADJUSTMENTS, Power
assisted steering (PAS) system - bleed.
31.Check and adjust front wheel alignment.

+ STEERING, ADJUSTMENTS, Front
wheel alignment - check & adjust.

STEERING
57-8 REPAIRS
Gaiter - PAS rack
$% 57.10.29
Remove
1.Remove PAS rack.

+ STEERING, REPAIRS, Power
steering rack.
2.Hold PAS rack securely and remove 2 Torx
bolts securing track rods. Discard bolts.
3.Remove support plate.
4.Remove track rods and spacers.
CAUTION: Note orientation of spacers
before dismantling.
5.Remove clips from PAS rack ram feed pipes.
6.Loosen 4 pipe unions and remove both ram
feed pipes.
CAUTION: Always fit plugs to open
connections to prevent contamination.
7.Remove clamp bolt from fluid pipe support
bracket and remove bracket.
8.Remove 2 gaiter securing clips.9.Remove gaiter sealing ring.
10.Remove gaiter.
11.Remove gaiter sealing band.
12.Remove slider and clip assembly.
13.Remove clip from slider.
Refit
1.Clean remains of lubricant from PAS rack slider
and clip.
2.Fit clip to slider and fit slider assembly to PAS
rack.
3.Apply grease supplied in the gaiter kit to
exposed rack shaft, slider and clip.
4.Fit gaiter sealing band.
5.Fit gaiter.
6.Fit gaiter sealing ring.
7.Align gaiter to slider and having ensured slider
is correctly located, use track rod securing bolts
to hold gaiter in position, without tightening
bolts, so to activate Loctite.
CAUTION: Do not screw bolts in more than
4 or 5 turns.
8.Ensure gaiter is not twisted, and fit gaiter
securing clips.
9.Fit fluid pipe support bracket and secure with
bolt.
10.Ensure pipe unions and rack ports are clean.
11.Fit both ram feed pipes and tighten small
diameter pipe to 18 Nm (13 lbf.ft)and large
diameter pipe to 24 Nm (18 lbf.ft).
12.Fit clips to pipes.
13.Remove track rod bolts securing bolts used to
align gaiter, fit spacers, track rods and support
plate to PAS rack.
CAUTION: Ensure spacers are aligned and
fitted correctly.
14.Hold track rods parallel with PAS rack and
tighten new Torx bolts to 100 Nm (74 lbf.ft).
15.Fit PAS rack.

+ STEERING, REPAIRS, Power
steering rack.

STEERING
REPAIRS 57-9
Oil cooler - Td4 & K1.8 models
$% 57.15.11
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover if fitted.

+ ENGINE - Td4, REPAIRS, Cover -
engine acoustic - Up to 02.5 Model Year.
3. Td4 models: Release and remove air intake
duct.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Ducting - intake assembly.
4. Td4 models: Loosen 2 clips and remove
intercooler outlet hose.
5. Td4 models: Remove dipstick for access.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Remove bolt securing PAS oil cooler pipe lower
mounting bracket to body.
7.Remove bolt securing PAS oil cooler pipe to RH
suspension turret.8.Place a suitable container beneath PAS
reservoir, release clip and disconnect return
hose from mount. Allow fluid to drain.
9.Place container beneath PAS quick release
pipe fitting.
10.Clean area surrounding quick release
connection.
11.Using LRT-57-044, disconnect cooler quick
release hose.
12.Release PAS reservoir from mounting bracket
and move aside.
13.Remove PAS oil cooler from vehicle.
NOTE: Do not carry out further dismantling if
component is removed for access only.

M12 6972

M57 1047

STEERING
57-10 REPAIRS
14.Remove clips from PAS oil cooler.
Refit
1.Clean cooler mounting points.
2.Fit clips to PAS cooler.
3.Fit PAS oil cooler to vehicle.
4.Connect quick release pipe fitting.
5.Align PAS pipe bracket, fit bolt and tighten to 10
Nm (7 lbf.ft).
6.Fit bolt to clip securing PAS pipe to RH turret,
tighten to 10 Nm (7 lbf.ft).
7.Fit PAS reservoir to mounting bracket.
8.Clean PAS fluid reservoir around filler cap and
fluid level indicators.
9.Fit PAS return hose to reservoir and secure
clip.
10. Td4 models: Fit intercooler outlet hose and
tighten clips.
11. Td4 models: Fit intake duct to body and duct
assembly.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Ducting - intake assembly.
12. Td4 models: Fit engine oil dipstick.
13. Fit engine acoustic cover if fitted.

+ ENGINE - Td4, REPAIRS, Cover -
engine acoustic - Up to 02.5 Model Year.
14.Connect battery earth lead.
15.Bleed PAS system.

+ STEERING, ADJUSTMENTS, Power
assisted steering (PAS) system - bleed.
Oil cooler - KV6 models
$% 57.15.11
Remove
1.Remove front bumper.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
2.Position container below PAS pipes to catch
fluid spillage.
3.Using LRT-57-044 release and disconnect
PAS hoses from oil cooler.
4.Remove 2 bolts and remove PAS fluid cooler.
Refit
1.Fit fluid cooler and tighten bolts to 10 Nm (7
lbf.ft).
2.Clean connections.
3.Connect hoses to fluid cooler.
4.Fit front bumper.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5.Bleed PAS system.

+ STEERING, ADJUSTMENTS, Power
assisted steering (PAS) system - bleed.
M57 1204
LRT-57-044

STEERING
REPAIRS 57-11
Drive belt - K1.8
$% 57.20.02
Remove
1.Disconnect battery earth lead.
2.Turn steering on RH lock.
3.Remove 3 bolts securing RH splash shield to
body and remove shield.
4.Fit a 13 mm spanner to hexagon on belt
tensioner and rotate fully clockwise to release
tension on drive belt.
5.To hold tensioner in this position, fit a suitable
pin, not exceeding 3 mm diameter, through
centre of hexagon into tensioner backplate.
6.Remove and discard drive belt.Refit
1.Clean drive belt pulley grooves and ensure
grooves are not damaged.
2.Fit drive belt. Ensure belt is located correctly in
pulley grooves.
3.Release tension, remove retaining pin and
lower tensioner pulley onto drive belt.
4.Fit splash shield and secure with bolts.
5.Straighten steering.
6.Connect battery earth lead.