radiator LAND ROVER FREELANDER 2001 User Guide

COOLING SYSTEM - K SERIES KV6
REPAIRS 26-3-3
REPAIRS
Cooling fan and motor
$% 26.25.22
Remove
1.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
2.Remove 3 bolts securing LH cooling fan and
motor assembly to fan cowl. Remove fan and
motor assembly.
Refit
1.Position fan and motor assembly to fan cowl, fit
and tighten bolts to 5 Nm (4 lbf.ft).
2.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
Control unit - radiator cooling fan - 2002
MY On
$% 26.25.43
Remove
1.Disconnect battery earth lead.
2.Release multiplugs from clips and disconnect
2 body harness multiplugs.
3.Disconnect multiplugs from cooling fan motors
and release harness from clips on cooling fan
cowl.
4.Remove screw securing control unit.
5.Release control unit from fan cowl.
Refit
1.Carefully position control unit in cowl and
secure with screw.
2.Connect body harness multiplugs and secure
to cowl.
3.Secure LH and RH harness to retaining clips
and connect multiplugs.
4.Connect battery earth lead.

COOLING SYSTEM - K SERIES KV6
26-3-4 REPAIRS
Radiator assembly
$% 26.40.01
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Drain cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
4. Models without A/C: Remove bumper
valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5. Models without A/C:Remove 2 bolts securing
PAS fluid cooler to armature.
6. Models without A/C: Remove 4 nuts and 4
bolts securing armature to body and remove
armature.
7. Models with A/C: Remove A/C condenser.

+ AIR CONDITIONING, REPAIRS,
Condenser.
8.Release clips and remove top and bottom
hoses.
CAUTION: Always fit plugs to open
connections to prevent contamination.
9.Release clip and remove expansion hose from
radiator.10. If fitted:Remove 2 bolts and 4 scrivets securing
LH and RH radiator baffles and remove baffles.
11.Remove radiator upper retaining pegs from
bonnet locking platform. Ease top of radiator
forward.
12.Remove 4 bolts securing fan cowl to radiator.
13.Remove 2 cowl retaining clips from radiator.
M26 0947

COOLING SYSTEM - K SERIES KV6
REPAIRS 26-3-5
14.Release radiator from lower mountings and
remove from vehicle.
15.Remove radiator upper mounting extension
brackets.
16.Remove 4 rubber mountings from radiator.Refit
1.Fit mounting rubbers to radiator.
2.Fit upper support brackets to radiator.
3.Position fan cowl to radiator, fit and tighten
bolts to 5 Nm (4 lbf.ft).
4.Secure fan cowl to radiator with clips.
5.Fit radiator and engage lower mountings in
chassis.
6.Fit radiator upper mountings to bonnet locking
platform.
7. If fitted:Position LH and RH radiator baffles,
secure with scrivets, fit and tighten top bolts to
5 Nm (4 lbf.ft).
8.Connect expansion tank hose and secure with
clip.
9.Connect bottom and top hoses to radiator
secure with clips.
10. Models with A/C: Fit A/C condenser.

+ AIR CONDITIONING, REPAIRS,
Condenser.
11. Models without A/C: Position armature, fit and
tighten 4 nuts and bolts securing armature to
body.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
12. Models without A/C: Align PAS fluid cooler
and tighten bolts to 8 Nm (6 lbf.ft).
13. Models without A/C: Fit bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
14.Refill cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
15.Fit acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
16.Connect battery earth lead.
M26 0946

PANEL REPAIRS
WELDING PROCEDURES 77-2-15
WE LDING PROCEDURE S
ECU locations (3 door model shown, 5
door model similar)
1Central control unit (on forward side of
passenger compartment fusebox, behind
driver's glove box)
2RF Receiver (on top of instrument pack)
3Immobiliser ECU (rear of fascia)
4DCU (SRS on transmission tunnel below
heater)
5EAT ECU (inside Environmental 'E' box)
6ECM (inside 'E' box)
7Fuel Burning Heater (behind wheelarch liner)
'Diesel only'8Cooling Fan Ecu (rear of radiator housing) all
models except 1.8
9ABS ECU (RH side front of engine
compartment)
10Folding door mirror ECU (on transmission
tunnel under centre console)
11Window lift ECU (on driver `A` post)
12Cruise Control Interface ECU (under R/H seat)
13Cruise control ECU (under R/H seat)

PANEL REPAIRS
REPAIRS 77-2-25
REPAIRS
Front bulkhead assembly
In this procedure, the crossmember gusset plates
are replaced in conjunction with the front bulkhead
assembly.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5.Remove front bumper armature.
6.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
7.Remove PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
8.Remove LH and RH headlamps.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
9.Release wiring to headlamps and position
aside.
10.Remove LH and RH engine bay shields.
11.Remove bumper valance LH and RH
attachment brackets.
12.Remove battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
13.Remove air intake hose.
14.Remove horn.

+ SECURITY, REPAIRS, Horn.
15.Remove windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
16.Remove bonnet lock.
17.Support bonnet in open position.
18.Remove bonnet stay. 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.

PANEL REPAIRS
77-2-26 REPAIRS
Refit
1.Fit bonnet stay.
2.Fit bonnet lock.
3.Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
4.Fit horn.

+ SECURITY, REPAIRS, Horn.
5.Fit air intake hose.
6.Fit battery. Do not connect earth lead.

+ CHARGING AND STARTING,
REPAIRS, Battery.
7.Fit bumper valance LH and RH attachment
brackets.
8.Fit LH and RH engine bay shields.
9.Fit LH and RH headlamps.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY. Secure headlamps
wiring.
10.Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
11.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
12.Fit front bumper armature.
13.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
14.Connect all ECUs.
15.Connect alternator.
16.Connect battery earth lead.

PANEL REPAIRS
REPAIRS 77-2-27
Bonnet locking platform
In this procedure the bonnet locking platform
reinforcement is also replaced in conjunction with the
bonnet locking platform.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
6.Remove both headlamp assemblies.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
7.Remove horn.

+ SECURITY, REPAIRS, Horn.
8.Remove battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
9.Remove air intake hose.
10.Remove bonnet lock.
11.Support bonnet in open position.
12.Remove bonnet stay.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Refit
1.Fit bonnet stay.
2.Fit bonnet lock.
3.Fit air intake hose.
4.Fit battery. Do not connect earth lead.

+ CHARGING AND STARTING,
REPAIRS, Battery.
5.Fit horn.

+ SECURITY, REPAIRS, Horn.
6.Fit both headlamp assemblies.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
7.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
8.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
9.Connect all ECUs.
10.Connect alternator.
11.Connect battery earth lead.

PANEL REPAIRS
77-2-28 REPAIRS
Headlamp mounting panel
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5.Remove front bumper armature.
6.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
7.Remove headlamp assembly.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
8.Release wiring to headlamp and position aside.
9. LH side: Remove front bumper LH support
bracket.
10. LH side: Remove battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
11. LH side: Remove horn.

+ SECURITY, REPAIRS, Horn.
12. LH side: Remove air intake hose.
13. RH side: Remove front bumper RH support
bracket.
14. RH side: Remove windscreen washer
reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
15. RH side: Remove PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.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. LH side: Fit air intake hose.
2. LH side: Fit horn.
3. LH side: Fit battery. Do not connect earth lead.

+ CHARGING AND STARTING,
REPAIRS, Battery.
4. LH side: Fit front bumper LH support bracket.
5. RH side: Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
6. RH side: Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
7. RH side: Fit front bumper LH support bracket.
8.Fit headlamp assembly.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.Secure headlamp
wiring.
9.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
10.Fit front bumper armature.
11.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
12.Connect all ECUs.
13.Connect alternator.
14.Connect battery earth lead.

PANEL REPAIRS
REPAIRS 77-2-29
Front lower crossmember
In this procedure, the crossmember gusset plates
are replaced in conjunction with the front lower
crossmember.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove LH and RH engine bay shields.
5.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
6.Remove front bumper armature.
7.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
8.Remove PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
9.Release wiring for LH and RH headlamps and
position aside.
Repair1.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. The front lower crossmember assembly
is only supplied with a limited amount of
spotwelds. Ensure that the correct amount of
plug welds are put onto the assembly as a
substitute for the spotwelds, see illustration
below.
Refit
1.Secure wiring to LH and RH headlamps.
2.Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
3.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
4.Fit front bumper armature.
5.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
6.Fit LH and RH engine bay shields.
7.Connect all ECUs.
8.Connect alternator.
9.Connect battery earth lead.

PANEL REPAIRS
77-2-30 REPAIRS
Front sidemember (complete)
In this procedure, the front sidemember closing
panel and the related crossmember to sidemember
gusset plate are replaced in conjunction with the front
sidemember.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
6.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
7.Remove front bumper armature.
8.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
9.Remove PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
10.Remove headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
11.Release wiring to headlamp and position aside.
12.Remove engine bay shield.
13.Remove front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
14.Remove front suspension rear beam.
15.Remove engine and gearbox.

+ ENGINE - K SERIES KV6, REPAIRS,
Engine and automatic gearbox - up to 03MY.
16.Remove PAS rack.

+ STEERING, REPAIRS, Power
steering rack.
17.Remove fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
18. LH side: Remove front bumper LH support
bracket.
19. LH side: Remove LH engine mounting from
body.
20. LH side: Remove battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
21. LH side: Remove air intake hose.
22. LH side: Remove horn.

+ SECURITY, REPAIRS, Horn.
23. RH side: Remove front bumper RH support
bracket.24. RH side: Remove RH engine mounting from
body.
25. RH side: Remove windscreen washer
reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
26. Driver's side: Remove passenger
compartment fuse box.
27. Driver's side: Remove brake pedal box and
brake servo.
28. Driver's side: Remove clutch pedal box.
29.Remove treadplate from front door aperture.
Release front carpet and position aside.
30.Remove insulation pads from engine bulkhead.