brake LAND ROVER FREELANDER 2001 Workshop Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 2001, Model line: FREELANDER, Model: LAND ROVER FREELANDER 2001Pages: 1007, PDF Size: 23.47 MB
Page 577 of 1007
BRAKES
70-28 REPAIRS
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 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 battery carrier.
+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
13.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
14.Remove stand and lower vehicle.
15.To ensure correct operation, the ABS system
MUST be tested using TestBook/T4.
Page 578 of 1007
BRAKES
REPAIRS 70-29
Sensor & harness - rear wheel
$% 70.65.31
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.Release ABS sensor multiplug from body clip
and disconnect multiplug.
4.Release ABS sensor harness from 3 grommets
on suspension and body brackets.
5.Release harness from clip on rear brake hose.6.Remove bolt securing ABS sensor to hub, if
fitted.
7.Release sensor from rear hub and remove
sensor and harness.
8.Remove bush from rear hub.
Refit
1.Clean sensor and rear hub mating faces.
2.Fit new bush to rear 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 bolt securing ABS sensor to hub, if fitted.
6.Ensure 'O' ring is in place and connect sensor
multiplug to body harness.
7.Secure multiplug in body clip.
8.Secure harness grommets to brackets.
9.Secure harness to brake hose clip.
10.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
11.Remove stands and lower vehicle.
12.To ensure correct operation, the ABS system
MUST be tested using TestBook/T4.
Page 579 of 1007
BRAKES
70-30 REPAIRS
Modulator unit
$% 70.65.49
Remove
1. Td4 and KV6 models: Remove engine
accoustic cover if fitted.
+ ENGINE - Td4, REPAIRS, Cover -
engine acoustic - Up to 02.5 Model Year.
2. Td4 and KV6 models: Release and remove air
intake hose.
3. Td4 and KV6 models: Release clip securing
harness and intake duct to body.
4. Td4 and KV6 models: Lift duct from body,
release clip from washer reservoir filler hose.
5. Td4 and KV6 models: Release and remove air
intake duct.
6. Td4 models: Loosen 2 clips and remove
intercooler outlet hose.7.Remove 2 bolts securing PAS oil cooler pipes.
8.Release PAS reservoir from mounting bracket
and position aside.
9.Release catch and disconnect ABS modulator
multiplug.
10.Position cloth under modulator to absorb fluid
spillage.
CAUTION: Brake fluid will damage paint
finished surfaces. If spilled, immediately
remove fluid and clean area with water.
11.Disconnect 2 inlet brake pipes unions from ABS
modulator.
12.Disconnect 4 outlet brake pipes unions from
ABS modulator.
CAUTION: Always fit plugs to open
connections to prevent contamination.
13.Remove 3 bolts securing ABS modulator to
mounting bracket.
14.Release and remove ABS modulator from
mounting bracket.
M70 1085
M70 1083
M70 1088
Page 580 of 1007
BRAKES
REPAIRS 70-31
Refit
1.Position modulator to mounting bracket fit bolts
and tighten to 9 Nm (7 lbf.ft).
2.Clean brake pipe unions.
3.Connect brake pipe unions to modulator
ensuring pipes are connected to their correct
ports.
4.Tighten unions to 17 Nm (12 lbf.ft).
5.Connect ABS modulator multiplug and secure
catch.
6. Td4 and KV6 models: Position air intake duct
to body.
7. Td4 and KV6 models: Secure intake duct to
washer bottle filler neck and harness clip.
8. Td4 and KV6 models: Fit air intake hose.
9.Fit PAS reservoir to mounting bracket.
10.Fit bolts securing PAS oil cooler pipes and
tighten to 10 Nm (7.5 lbf.ft).
11. Td4 models: Fit intercooler outlet hose and
tighten clips.
12. Td4 and KV6 models: Fit engine accoustic
cover if fitted.
+ ENGINE - Td4, REPAIRS, Cover -
engine acoustic - Up to 02.5 Model Year.
13.Bleed brakes.
+ BRAKES, ADJUSTMENTS, Brake
bleed.
14.To ensure correct operation, the ABS system
MUST be tested using TestBook/T4.
Switch - hill descent - from 04MY
$% 70.70.11
Remove
1.Working from forward edge, carefully release
spring clip securing gear selector indicator
assembly to centre console. Release 2
additional clips at the sides and slide assembly
forward.
2.Disconnect multiplug from hill descent switch.
3.Remove hill descent switch from gear selector
indicator assembly.
Refit
1.Fit and secure hill descent switch to gear
selector indicator assembly.
2.Connect hill descent control switch multiplug.
3.Fit and secure gear selector indicator assembly
to centre console.
Page 581 of 1007
BRAKES
70-32 REPAIRS
Switch - hill descent - up to 03MY
$% 70.70.13
Remove
1.Remove gear lever knob.
2.Release gaiter from hill descent control switch.
3.Disconnect multiplug from switch.
4.Remove bolt and hill descent switch.
Refit
1.Fit hill descent switch and tighten bolt to 5 Nm
(3.5 lbf.ft).
2.Connect multiplug.
3.Fit gaiter.
4.Fit gear lever knob.
Page 785 of 1007
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.
Page 786 of 1007
PANEL REPAIRS
REPAIRS 77-2-31
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 engine bulkhead.
2.Position front carpet and fit treadplate to front
door aperture. 3. Driver's side: Fit clutch pedal box.
4. Driver's side: Fit brake pedal box and brake
servo.
5. Driver's side: Fit passenger compartment fuse
box.
6. LH side: Fit horn.
+ SECURITY, REPAIRS, Horn.
7. LH side: Fit air intake hose.
8. LH side: Fit battery. Do not connect battery
earth lead.
+ CHARGING AND STARTING,
REPAIRS, Battery.
9. LH side: Fit LH engine mounting to body.
10. LH side: Fit front bumper LH support bracket.
11. RH side: Fit windscreen washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
12. RH side: Fit RH engine mounting to body.
13. RH side: Fit front bumper RH support bracket.
14.Fit fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
15.Fit PAS rack.
+ STEERING, REPAIRS, Power
steering rack.
16.Fit engine and gearbox.
+ ENGINE - K SERIES KV6, REPAIRS,
Engine and automatic gearbox - up to 03MY.
17.Fit front suspension rear beam.
18.Fit front wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
19.Fit engine bay shield.
20.Fit headlamp.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
21.Secure headlamp wiring.
22.Fit PAS fluid cooler.
+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
23.Fit radiator.
+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
24.Fit front bumper armature.
25.Fit front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
26.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
27.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
28.Connect all ECUs.
29.Connect alternator.
30.Connect battery earth lead.
Page 789 of 1007
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.
Page 791 of 1007
PANEL REPAIRS
77-2-36 REPAIRS
Valance upper front
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove front wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
6.Remove front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
7.Remove front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
8.Remove headlamp.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
9.Release wiring from valance and position
aside.
10. LH side: Remove ECM.
11. LH side: Remove battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
12. RH side: Remove PAS fluid reservoir.
13. RH side: Remove brake pipes from valance.
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 battery. Do not connect earth lead.
+ CHARGING AND STARTING,
REPAIRS, Battery.
2. LH side: Fit ECM.
3. RH side: Fit PAS fluid reservoir.
4. RH side: Fit brake pipes to valance. Bleed
brakes.
+ BRAKES, ADJUSTMENTS, Brake
bleed.
5.Secure wiring to valance.
6.Fit headlamp.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
7.Fit front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
8.Fit front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
9.Fit front wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
10.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
11.Connect all ECUs.
12.Connect alternator.
13.Connect battery earth lead.
Page 792 of 1007
PANEL REPAIRS
REPAIRS 77-2-37
Valance front
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove front wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
6.Remove engine bay shield.
7.Remove front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
8.Remove front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
9.Remove front bumper support bracket.
10.Remove radiator.
+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
11.Remove headlamp.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
12.Release wiring to headlamp and position aside.
13. LH side: Remove air cleaner.
14. LH side: Remove air intake hose.
15. LH side: Remove ECM.
16. LH side: Remove battery carrier.
+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
17. LH side: Remove engine compartment fuse
box and related wiring.
18. LH side: Remove LH front brake pipe.
19. RH side: Remove PAS fluid reservoir.
20. RH side: Remove RH front brake pipe.
21. RH side: Remove windscreen washer
reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
22. 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.