2001 LAND ROVER FREELANDER Workshop Manual

BRAKES
70-20 REPAIRS
Vacuum pump - Td4 - manual
$% 70.50.19
Remove
1.Disconnect battery earth lead.
2.Remove air cleaner element.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Element - air cleaner.
3.Move injector harness clear of vacuum pump.
4.Release clip and disconnect hose from vacuum
pump.
5.Remove and discard 2 bolts securing vacuum
pump.
6.Remove vacuum pump and discard 'O' ring.Refit
1.Clean vacuum pump and mating face.
2.Fit new 'O' ring to vacuum pump.
3.Rotate vacuum pump drive to align with
camshaft, fit vacuum pump and tighten new
bolts to 22 Nm (16 lbf.ft).
4.Connect hose to vacuum pump and secure with
clip.
5.Reposition injector harness.
6.Fit air cleaner element.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Element - air cleaner.
7.Connect battery earth lead.
M70 1031

BRAKES
REPAIRS 70-21
Vacuum pump - Td4 - automatic
$% 70.50.19
Remove
1.Disconnect battery earth lead.
2.Remove camshaft cover.

+ ENGINE - Td4, REPAIRS, Gasket -
camshaft cover.
3.Mark EGR pipe and cooler to aid refit.
4.Loosen clamps EGR pipes to cooler and move
clamps aside.
5.Remove pipe, EGR cooler to EGR valve.
6.Remove bolt securing fuel rails to support
bracket.
7.Remove bolt securing intercooler pipe to
support bracket.
8.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.9.Remove bolt securing turbo outlet pipe to upper
coolant rail.
10.Remove 2 bolts securing pipe support bracket
to engine lifting bracket, remove support
bracket.
11.Release clip and remove vacuum hose.
12.Remove and discard 2 bolts securing vacuum
pump.

M17 0283

BRAKES
70-22 REPAIRS
13.Remove 3 bolts securing EGR cooler to
cylinder head and lifting bracket.
14.Move EGR cooler aside for access to vacuum
pump.
15.Remove vacuum pump and discard 'O' ring.
Refit
1.Clean vacuum pump and mating face.
2.Fit new seal to vacuum pump, fit vacuum pump
and tighten new bolts to 22 Nm (16 lbf.ft).
3.Position EGR cooler to mounting, fit bolts and
tighten to 25 Nm (18 lbf.ft).
4.Position pipe support bracket to engine lifting
bracket, fit and tighten bolts to 25 Nm (18 lbf.ft).
5.Fit vacuum hose and tighten clip.
6.Fit bolt securing turbocharger pipe to coolant
rail and tighten to 25 Nm (18 lbf.ft).
7.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
8.Fit bolt securing turbocharger intercooler pipe
to support bracket and tighten to 10 Nm (7.5
lbf.ft).
9.Fit bolt securing fuel rails to support bracket
and tighten to 10 Nm (7.5 lbf.ft).
10.Align EGR pipe to cooler, fit clamp but do not
fully tighten until camshaft cover is refitted.
11.Fit EGR pipe clamp and tighten screw.
12.Fit camshaft cover.

+ ENGINE - Td4, REPAIRS, Gasket -
camshaft cover.
13.Connect battery earth lead.
Vacuum - enhancer - KV6
$% 70.50.20
Remove
1.Disconnect battery earth lead.
2.Remove engine accoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Release enhancer from support clips.
4.Disconnect multiplug from solenoid valve if
fitted.
5.Release and disconnect servo pipe.
6.Release clip and disconnect from intake hose.
7.Release and remove enhancer assembly from
inlet manifold.
Refit
1.Fit enhancer to inlet manifold.
2.Connect to intake hose and secure with clip.
3.Connect servo hose.
4.Connect multiplug to solenoid valve if fitted.
5.Fit enhancer into clips.
6.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
7.Connect battery earth lead.

BRAKES
REPAIRS 70-23
Carrier assembly - calliper - front
$% 70.55.28
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 road wheel.
3.Remove 2 guide pins from calliper housing.
4.Release calliper housing from calliper carrier
and tie aside.
5.Remove 2 brake pads and retainers from
calliper carrier.6.Remove 2 bolts securing calliper carrier and
remove carrier.
7.Remove guide pins and seals from carrier.

BRAKES
70-24 REPAIRS
Refit
1.Clean guide pins and carrier mating faces.
2.Fit guide pins and seals to carrier.
3.Fit carrier, fit bolts and tighten to 100 Nm (74
lbf.ft).
4.Rotate disc by hand and scrape all scale and
rust from around edge of disc. Clean location
surfaces on calliper bracket.
5.Clean dust from brake parts using brake
cleaning fluid.
WARNING: Do not use an air line to blow
dust from brake assembly. Do not use
petroleum based fluid as damage will occur
to rubber components.
6.Clean mating faces of calliper and hub.
7.Fit pad retainers to calliper bracket.
8.Fit brake pads to calliper carrier.
The leading edge of the pads have chamfers
on them, the chamfers are asymmetric. It is
imperative that the pads are correctly fitted.
Pad 'A' in illustration must be fitted to the
inboard side of the calliper. Pad 'B' must be
fitted to the outboard side of the calliper.
9.Position calliper housing to carrier, align flats
on guide pins with calliper housing.
10.Ensure flats on guide pins locate with lugs on
calliper housing. Fit bolts and tighten to 27 Nm
(20 lbf.ft).
11.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
12.Remove stands and lower vehicle.
Wheel cylinder - rear
$% 70.60.19
Remove
1.Raise rear 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 road wheel.
3.Remove rear brake shoes.

+ BRAKES, REPAIRS, Brake Shoes -
rear set.
4.Disconnect pipe union from wheel cylinder.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove 2 bolts securing wheel cylinder and
remove wheel cylinder.
6.Use a wire brush to remove any corrosion.
7.Clean backplate and drum with brake cleaning
fluid.
WARNING: Do not use an air line to blow
dust from brake assembly. Do not use
petroleum based fluid as damage will occur
to rubber components.
Refit
1.Fit wheel cylinder to backplate, fit bolts and
tighten to 8 Nm (6 lbf.ft).
2.Connect brake pipe union to wheel cylinder and
tighten union to 17 Nm (12 lbf.ft).
3.Fit brake shoes.

+ BRAKES, REPAIRS, Brake Shoes -
rear set.
4.Bleed brakes.

+ BRAKES, ADJUSTMENTS, Brake
bleed.
5.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
6.Remove stands and lower vehicle.
M70 1148
AB

BRAKES
REPAIRS 70-25
Switch - low fluid level
$% 70.65.06
Remove
1.Disconnect brake fluid level multiplug.
2.Release retaining pin and remove fluid level
switch.
Refit
1.Clean brake fluid level switch.
2.Fit brake fluid level switch.
3.Connect multiplug to brake fluid level switch.
Sensor & harness - front wheel - RH
$% 70.65.29
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 road wheel.
3.Remove front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
4.Locate ABS sensor harness on inner wing.
5.Release ABS sensor multiplug from body clip
and disconnect multiplug.
6.Release grommet from wing valance and pull
harness through.

BRAKES
70-26 REPAIRS
7.Release 2 grommets from wing valance and
damper brackets
8.Release harness from brake hose clips.
9.Remove bolt securing ABS sensor to hub, if
fitted.
10.Release ABS sensor from hub.
11.Remove ABS sensor and harness.
12.Remove bush from front hub.Refit
1.Clean ABS sensors and mating faces.
2.Fit new bush to front hub.
3.Apply anti-seize grease to sensor.
4.Fit sensor to hub, ensure sensor is fully seated
in hub.
CAUTION: Ensure ABS sensor is fully
located into hub, so that sensor touches
pole wheel teeth.
5.Fit and tighten bolt securing ABS sensor to hub,
if fitted.
6.Secure harness grommets to brackets.
7.Pass sensor harness through wing valance and
secure grommet.
8.Ensure 'O' ring is in place and connect sensor
multiplug to body harness.
9.Secure multiplug in body clip.
10.Secure harness to brake hose clip.
11.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
12.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
13.Remove stand and lower vehicle.
14.To ensure correct operation, the ABS system
MUST be tested using TestBook/T4.

BRAKES
REPAIRS 70-27
Sensor & harness - front wheel - LH
$% 70.65.30
Remove
1.Remove battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
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 road wheel.
4.Remove front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
5.Locate ABS sensor harness on inner wing.
6.Release ABS sensor multiplug from body clip
and disconnect multiplug.
7.Release grommet from wing valance and pull
harness through.8.Release 2 grommets from wing valance and
damper brackets
9.Release harness from brake hose clips.
10.Remove bolt securing ABS sensor to hub, if
fitted.
11.Release ABS sensor from hub.
12.Remove ABS sensor and harness.
13.Remove bush from front hub.