2001 LAND ROVER FREELANDER engine coolant

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-15
26.Disconnect 2 fluid cooler hose unions and
discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
27.Release 2 clips and disconnect coolant hoses
from fluid cooler.
28.Remove bolts securing fluid cooler.
29.Remove fluid cooler.30.Remove bolt securing CKP sensor to gearbox,
release sensor and position aside.
31.Remove nut and bolt, adjacent to CKP sensor,
securing gearbox to engine.
32.Fit suitable lifting brackets to gearbox and
secure with nuts and bolts.
33.Connect lifting equipment to brackets.
34.Remove 2 bolts securing gearbox to engine.
M44 1639
M44 1665
M44 1651

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-17
21.Position access plate, fit bolts and tighten to 9
Nm (7 lbf.ft).
22.Clean mating faces of IRD and gearbox.
23.Lubricate and fit new 'O' ring.
24.With assistance, fit IRD.
25.Fit bolts securing IRD to gearbox and tighten
sufficiently only to pull mating faces of IRD and
gearbox together at this stage.
26.Fit IRD support bracket and tighten bolts
sufficiently only to pull mating faces together.
27.Final tighten bolts securing IRD to gearbox to
80 Nm (59 lbf.ft).
28.Final tighten bolts securing IRD support
bracket in following sequence:5 bolts securing
support bracket to IRD 50 Nm (37 lbf.ft), 2 bolts
securing support bracket to engine front
mounting bracket 50 Nm (37 lbf.ft), 3 bolts
securing support bracket to sump 45 Nm (33
lbf.ft).
29.Position lower engine steady, 'TOP' mark
uppermost. Fit bolt but do not tighten at this
stage.
30.Connect coolant hoses and secure with clips.
31.Connect breather hose to IRD housing.
32.Fit manifold heat shield and fit nut securing
heat shield to pinion housing finger tight.
33.Fit bolts securing manifold heat shield to IRD
support bracket and tighten to 9 Nm (7 lbf.ft).
34.Fit nut securing heat shield to IRD and tighten
to 45 Nm (33 lbf.ft).
35.Final tighten nut securing manifold heat shield
to IRD pinion housing to 25 Nm (18 lbf.ft).
36.Clean exhaust manifold and mating face on
cylinder head.
37.Fit exhaust manifold gasket.
38.Position exhaust manifold, fit nuts and
progressively tighten, from centre outwards to
45 Nm (33 lbf.ft).
39.Connect HO2S multiplug and secure to support
bracket.
Gearbox - KV6
$% 44.20.02.99
Remove
1.Tie bonnet back in upright position.
2.Disconnect battery earth lead.
3.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
4.Remove IRD.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.
5.Loosen selector cable trunnion nut.
6.Release clip securing selector cable to gearbox
bracket, remove selector cable and collect
trunnion from selector lever.
7.Remove 3 screws securing LH splash shield
and remove shield.

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.

FRONT SUSPENSION
60-8 REPAIRS
9.Remove upper nut from anti-roll bar link,
release link and position aside.
CAUTION: Use a spanner and an Allen key
to prevent ball joint rotating when undoing
link.
10.Remove 2 nuts and bolts securing hub to
damper.
11.Release damper from hub.12. LH side: Remove 2 bolts securing positive and
negative leads to fusebox.
13. LH side: Disconnect multiplug from engine
compartment fuse box.
14. LH side: Release leads and position aside.
15. LH side: Remove 3 nuts securing fusebox and
position fusebox aside.
16. RH side: Remove bolt securing coolant
reservoir and position reservoir aside.
17.Reference mark top mounting in relationship to
body.
18.Remove 3 nuts from damper top mounting and
remove spring and damper assembly.

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.

PANEL REPAIRS
77-2-34 REPAIRS
26. LH side: Remove LH engine mounting from
body.
27. LH side: On models with Diesel engines,
remove fuel filter.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Filter - main - up to 03MY.
28. LH side: Remove LH front brake pipe.
29. RH side: Remove front bumper RH support
bracket.
30. RH side: Remove windscreen washer
reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
31. RH side: Remove coolant expansion tank.
32. RH side: Remove RH engine mounting from
body.
33. RH side: Remove PAS fluid reservoir.
34. RH side: Remove RH front brake pipe.
35. Driver's side: Remove passenger
compartment fuse box.
36.Remove brake pedal box and brake servo.
37.Remove clutch pedal box.
38.Release vehicle harness from valance and
position aside.
39.Remove treadplate from front door aperture.
Release front carpet and position aside.
40.Remove insulation pads from engine bulkhead.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown. Refit
1.Fit insulation pads to front and rear sides of
engine bulkhead.
2.Position front carpet and fit treadplate to front
door aperture.
3.Secure vehicle harness to valance.
4. Driver's side: Fit clutch pedal box.
5.Fit brake pedal box and brake servo.
6.Fit passenger compartment fuse box.
7. LH side: Fit LH front brake pipe. Bleed brake
system.
+ BRAKES, ADJUSTMENTS, Brake
bleed.
8. LH side: On models with Diesel engines, fit fuel
filter.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Filter - main - up to 03MY.
9. LH side: Fit LH engine mounting to body.
10. LH side: Fit engine compartment fuse box and
related wiring.
11. LH side: Fit battery carrier. Do not connect
battery earth lead.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
12. LH side: Fit engine compartment fusebox.
13. LH side: Fit ECM.
14. LH side: Fit air intake hose.
15. LH side: Fit air cleaner.
16. LH side: Fit front bumper LH support bracket.
17. RH side: Fit RH front brake pipe. Bleed brake
system.

+ BRAKES, ADJUSTMENTS, Brake
bleed.
18. RH side: Fit PAS fluid reservoir.
19. RH side: Fit RH engine mounting to body.
20. RH side: Fit coolant expansion tank.
21. RH side: Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
22. RH side: Fit front bumper RH support bracket.
23.Fit fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
24.Fit PAS rack.

+ STEERING, REPAIRS, Power
steering rack.
25.Fit front damper.

+ FRONT SUSPENSION, REPAIRS,
Damper.
26.Fit engine and gearbox.

+ ENGINE - K SERIES KV6, REPAIRS,
Engine and automatic gearbox - up to 03MY.
27.Fit front suspension rear beam.
28.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.