coolant reservoir LAND ROVER FREELANDER 2001 Workshop Manual

TORQUE WRENCH SETTINGS
06-28
Brakes
1 Use NEW bolts
TORQUE DESCRIPTION METRIC IMPERIAL
ABS ECU pipe unions 17 Nm 12 lbf.ft
ABS modulator to mounting bracket bolts 9 Nm 7 lbf.ft
ABS modulator mounting bracket to inner wing:
⇒ Nuts
⇒ Bolts13 Nm
8 Nm10 lbf.ft
6 lbf.ft
Bleed screw - front calipers 10 Nm 7.5 lbf.ft
Brake servo to bulkhead nuts 22 Nm 16 lbf.ft
EGR cooler to mounting bolts 25 Nm 18 lbf.ft
EGR pipe support bracket to engine lifting bracket bolts 25 Nm 18 lbf.ft
Front caliper brake hose banjo bolt 28 Nm 21 lbf.ft
Front caliper guide pin bolts 27 Nm 20 lbf.ft
Front caliper mounting bolts 100 Nm 74 lbf.ft
Front disc shield to hub screw 8.5 Nm 6.3 lbf.ft
Front disc to drive flange screws 5 Nm 3.7 lbf.ft
Fuel rail to support bracket bolt 10 Nm 7.5 lbf.ft
Handbrake cable to body and subframe bolts 22 Nm 16 lbf.ft
Handbrake cable retaining plate bolts 22 Nm 16 lbf.ft
Handbrake lever assembly to body bolts 22 Nm 16 lbf.ft
Hill Descent Control (HDC) switch bolt 5 Nm 3.5 lbf.ft
Master cylinder to servo nuts 25 Nm 18 lbf.ft
PAS oil cooler pipe bolts 10 Nm 7.5 lbf.ft
Primary and secondary brake pipe union nuts 17 Nm 12 lbf.ft
Rear wheel cylinder pipe union nut 17 Nm 12 lbf.ft
Rear wheel cylinder to backplate bolts 8 Nm 6 lbf.ft
Reservoir to master cylinder (LHD) Torx bolt 8 Nm 6 lbf.ft
Reservoir to master cylinder (LHD) Torx bolt 6 Nm 4.5 lbf.ft
Road wheel nuts 115 Nm 85 lbf.ft
Turbocharger intercooler pipe to support bracket bolt 10 Nm 7.5 lbf.ft
Turbocharger pipe to coolant rail bolt 25 Nm 18 lbf.ft
Vacuum pump bolts
122 Nm 16 lbf.ft
Vacuum reservoir to mounting bracket nut 10 Nm 7.5 lbf.ft

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.

FRONT SUSPENSION
60-10 REPAIRS
Refit
1.Inspect damper, spring mounting rubbers and
bearing for deterioration and damage.
2.Clean mating faces of spring, mounting and
mounting plate.
3.Clean damper shaft and bump stop plate.
4.Position spring and damper assembly to spring
compressor. Compress spring.
5.Fit damper to spring, ensure spring locates in
cut recess in damper plate.
6.Fit bump cup, bump stop and dust cover to
damper.
7.Fit spring aid and bump plate.
8.Fit mounting plate and rebound washer.
9.Using new nut, hold damper shaft with Allen
key and tighten nut to 57 Nm (42 lbf.ft).
CAUTION: Note alignment of top mounting,
spring and damper dust cover.
10.Release and remove spring from compressor.
11.Clean mating face of top mounting plate.
12.Position damper assembly and align top
mounting to body, fit nuts and tighten to 45 Nm
(33 lbf.ft).
13. LH side: Position fusebox, fit nuts and tighten
to 8 Nm (6 lbf.ft).
14. LH side: Connect positive and negative leads,
fit bolts and tighten to 8 Nm (6 lbf.ft).
15. LH side: Connect multiplug to fusebox.
16. RH side: Position coolant reservoir and secure
with bolt.
17.Fit hub to damper, fit nuts and bolts and tighten
to 205 Nm (151 lbf.ft).
18.Clean anti-roll bar link taper and mating face.
19.Connect anti-roll bar link, fit new nut and tighten
to 55 Nm (41 lbf.ft).
CAUTION: Use a spanner and an Allen key
to prevent ball joint rotating when undoing
link.
20.Clean track rod taper and mating face.
21.Connect track rod end to steering arm using
new nut and tighten nut to 55 Nm (41 lbf.ft).
22.Clean ABS sensor, smear sensor with an anti-
seize grease and fit sensor to hub.
CAUTION: Ensure ABS sensor is fully
located into hub, so that sensor touches
pole wheel teeth.
23.Position ABS harness and brake hose in
bracket and secure with clip.
24.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
25.Remove stand and lower vehicle.
26.Connect battery earth lead.
Lower arm assembly
$% 60.35.02
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 underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
4.Release stake in drive shaft nuts.
5.With an assistant applying brakes, remove and
discard drive shaft hub nut.
6.Remove clip securing brake hose to bracket on
damper.
7.Release ABS sensor harness and brake hose
from damper.
8.Release ABS sensor from hub.

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.

HARNESSES
86-7-2 REPAIRS
Harness - main
$% 86.70.07
Remove
1.Make the SRS system safe.

+ GENERAL INFORMATION,
Supplementary restraint system
precautions.
2.Remove carpet.
3.Remove engine acoustic cover.

+ ENGINE - Td4, REPAIRS, Cover -
engine acoustic - Up to 02.5 Model Year.
4.Remove windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
5.Pull reservoir harness and washer tubes into
engine bay.
6.Remove nut and release earth header from RH
inner wing.
7.Disconnect multiplug from ABS modulator.
8.Disconnect multiplug from RH ABS speed
sensor and release harness from clips.
9.Disconnect 2 multiplugs from RH headlamp
and headlamp levelling motor.10.Disconnect multiplugs from horn, refrigerant
pressure sensor and compressor.
11.Remove jack from holder in engine bay.
12.Disconnect multiplug from brake fluid low level
indicator switch.
13.Disconnect multiplug from bonnet switch.
14.Remove bolt and 2 nuts securing PAS and
coolant reservoir support bracket and position
aside.
15.Release 5 harness retaining clips.
16.Release front screen wash tube from harness
and position aside.
17.Remove nut securing earth header to bulk head
and remove earth header.

HARNESSES
REPAIRS 86-7-11
41.Position fuse box to body and connect
multiplugs.
42.Fit relays to fuse box bracket.
43.Connect coaxial cable.
44.Fit and connect multiplug to RH 'A' post.
45.Fit passenger compartment fuse box and
secure with bolts.
46.Position side repeater lamps, connect
multiplugs and fit to wings.
47.Secure rear edge of front wheel arch liners.
48.Fit front mud flaps and secure with screws.
49.With assistance feed harness through bulk
head into engine bay.
50.Position harness to wiper motor and connect
multiplug.
51.Fit air intake plenum.

+ HEATING AND VENTILATION,
REPAIRS, Plenum - air intake.
52.Secure harness to LH side of engine bay and
secure fixings.
53.Connect multiplug to inertia switch.
54.Connect multiplugs to underside of fuse box.
55.Fit nuts securing fuse box to brackets.
56.Fit battery connections and multiplug to fuse
box.
57.Fit fuse box cover.
58.Connect 'E' box cooling fan multiplug.
59.Connect 'E' box temperature sensor multiplug.
60.Connect engine harness multiplugs to main
harness.
61. Automatic gearbox only:Connect multiplug to
gearbox ECU.
62.Fit 'E' box cover and secure with Allen screws.
63.Connect engine harness multiplugs to main
harness.
64.Fit harness retaining clips.
65. Models with cruise control: Connect
multiplug to vacuum pump.
66.Connect Lucar connector to starter motor.
67.Connect multiplug to LH ABS speed sensor.
68.Fit LH earth header and secure with nut.
69.Connect multiplug to harness.
70.Connect multiplugs to LH headlamp and
headlamp levelling motor.
71.Secure harness to cooling fan clips.
72.Connect multiplugs to cooling fan pack and
cooling fans.
73.Position bonnet release cable to harness and
secure with cable ties.
74.Fit battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
75.With assistance feed harness through bulk
head into engine bay.
76.Fit earth header to bulk head and secure with
nut.
77.Fit front screen washer tube to harness.
78.Fit harness retaining clips.79.Fit PAS and coolant reservoir support bracket
and secure with bolt and nuts.
80.Connect multiplug to bonnet switch.
81.Connect multiplug to brake fluid low level
indicator switch.
82.Fit jack to holder in engine bay.
83.Connect multiplugs to horn, refrigerant
pressure sensor and compressor.
84.Connect multiplugs to RH headlamp and
headlamp levelling motor.
85.Connect multiplug to RH ABS speed sensor
and secure to clips.
86.Connect multiplug to ABS modulator.
87.Fit earth header to RH inner wing and secure
with nut.
88.Position harness to windscreen washer
reservoir.
89.Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
90.Fit engine acoustic cover.

+ ENGINE - Td4, REPAIRS, Cover -
engine acoustic - Up to 02.5 Model Year.
91.Fit carpet.