gearbox LAND ROVER FREELANDER 2001 Workshop Manual

HEATING AND VENTILATION
REPAIRS 80-11
Harness - positive temperature co-
efficient (PTC) heater - Td4 models
$% 80.20.06
Remove
1.Disconnect battery earth lead.
2.Remove bolt securing PTC cable from positive
side of battery.
3.Remove ECM from 'E' box.

+ ENGINE MANAGEMENT SYSTEM -
EDC, REPAIRS, Engine control module
(ECM).
4.Disconnect multiplugs from gearbox ECU and
cooling fan sensor5.Release harness from cable ties and release
relays from inner casing.
6.Release and disconnect cooling fan and joint
harness multiplugs.
7.Release 3 harnesses and air duct rubber
sleeve's from housing.
8.Release clips and remove fuse box cover.
9.Remove nut securing ECM housing.
10.Release housing from retaining brackets and
remove.
M80 0557

HEATING AND VENTILATION
REPAIRS 80-13
21.Disconnect 3 Lucar connections from PTC
element.
22.Release cable ties securing PTC harness to
main harness.
23.Remove air intake plenum.

+ HEATING AND VENTILATION,
REPAIRS, Plenum - air intake.
24.Release 2 clips securing PTC harness from
plenum box section.
25.With assistance release 2 grommets from
bulkhead and remove PTC harness from
vehicle.Refit
1.With assistance route PTC harness through
bulkhead and fit grommets.
2.Fit clips securing PTC harness to plenum box
3.Fit air intake plenum.

+ HEATING AND VENTILATION,
REPAIRS, Plenum - air intake.
4.Fit cable ties securing PTC harness to main
bulkhead harness.
5.Connect Lucar connections to PTC element.
6.Fit air duct.
7.Fit RH demister vent duct.
8.Fit fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
9.Connect and secure PTC harness multiplug to
engine harness.
10.Secure PTC harness/relay to bulkhead bracket
11.Fit clip to secure PTC harness to ECM housing
bracket.
12.Fit PTC positive leads to (80 amp) fuse holder,
fit and tighten nuts to 7 Nm (5.2 lbf.ft).
13.Fit (80 amp) fuse cover.
14.Secure PTC harness/relays to ECM housing
bracket.
15.Fit fuse box, ensure harness routing is clear
suspension turret. Tighten nuts to 10 Nm (7
lbf.ft).
16.Fit fuse box cover.
17.Fit 'E' box housing into securing brackets.
18.Fit and tighten nut securing housing.
19.Fit harness and air duct rubber sleeve's to
housing.
20.Fit harness cable tie and secure relay in
housing.
21.Connect and secure joint harness and cooling
fan multiplugs.
22.Connect cooling fan sensor and gearbox ECU
multiplugs.
23.Fit ECM into 'E' box.

+ ENGINE MANAGEMENT SYSTEM -
EDC, REPAIRS, Engine control module
(ECM).
24.Position PTC positive cable to battery and
secure with bolt, tighten to 25 Nm (18 lbf.ft).
25.Connect battery earth lead.

CHARGING AND STARTING
86-1-16 REPAIRS
Starter motor - KV6
$% 86.60.01
Remove
1.Remove battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
2.Release starter motor solenoid terminal cover,
remove nut securing battery lead to solenoid
and disconnect battery lead.
3.Disconnect Lucar connector from starter
solenoid.
4.Remove 3 bolts securing starter motor to
gearbox noting that the LH bolt also secures
the mounting bracket for the CKP sensor
multiplug.
5.Manoeuvre and remove starter motor.Refit
1.Clean starter motor and mating face on
gearbox.
2.Position starter motor to gearbox, align CKP
sensor multiplug bracket, fit and tighten bolts to
45 Nm (33 lbf.ft).
3.Connect battery lead to solenoid terminal, fit
nut and tighten to 13 Nm (9.5 lbf.ft). Secure
terminal cover.
4.Connect Lucar connector to starter solenoid.
5.Fit battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.

CHARGING AND STARTING
REPAIRS 86-1-17
Starter motor - K1.8
$% 86.60.01
Remove
1.Disconnect battery earth lead.
2.Remove air cleaner assembly.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Air cleaner - K1.8.
3.Disconnect Lucar connector from starter motor.
4.Remove nut and disconnect battery lead from
starter solenoid.
5.Remove lower nut and bolt securing starter
motor.
6.Remove bolt securing steady bar to engine LH
mounting.
7.Remove upper nut and bolt securing starter
motor.
8.Remove engine steady bar.
9.Remove starter motor.Refit
1.Clean starter motor and mating face.
2.Ensure gearbox closing plate is in position.
3.Fit starter motor and fit lower bolt but do not
tighten bolt at this stage.
4.Fit engine steady bar, fit bolt securing steady
bar to engine mounting but do not tighten at this
stage.
5.Fit starter motor upper bolt.
6.Tighten starter motor upper and lower nuts and
bolts to 80 Nm (59 lbf.ft).
7.Tighten bolt securing engine steady bar to LH
engine mounting to 25 Nm (18 lbf.ft).
8.Connect battery cable to starter solenoid, fit nut
and tighten to 8 Nm (6 lbf.ft).
9.Connect Lucar to solenoid.
10.Fit air cleaner assembly.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Air cleaner - K1.8.
11.Connect battery earth lead.

HARNESSES
86-7-4 REPAIRS
33. Automatic gearbox only: Disconnect
multiplug from automatic gearbox ECU.
34.Disconnect 2 engine harness to main harness
multiplugs.
35.Disconnect 'E' box temperature sensor
multiplug.
36.Disconnect 'E' box cooling fan multiplug.
37.Remove fuse box cover.
38.Remove 2 bolts securing battery connections to
fuse box and disconnect multiplug from fuse
box.
39.Remove 3 nuts securing fuse box to brackets.40.Disconnect 6 multiplugs from the underside of
fusebox.
41.Disconnect multiplug from inertia switch.
42.Release 2 fixings securing harness to LH side
of engine bay.
43.Remove air intake plenum.

+ HEATING AND VENTILATION,
REPAIRS, Plenum - air intake.

HARNESSES
REPAIRS 86-7-7
61.Disconnect heated oxygen sensor multiplug.
62. Automatic gearbox only: Disconnect
multiplugs from gear selector.
63.Disconnect multiplug from accelerometer.
64. Manual gearbox only: Disconnect multiplug
from gear lever hill descent switch.
65.Disconnect Lucar from handbrake switch.
66.Release 2 relays from bracket and remove
bracket.
67.Release 4 clips securing harness to air ducting.
68.Remove nut from rear heater ducting and
remove ducting.
69.Remove 4 nuts securing steering column to
bracket and lower column.
70.Remove face level vent ducting to access main
harness clips.71.Disconnect multiplug from window lift ECU.
72.Remove nut securing earth header to RH 'A'
post and release header.
73.Release multiplugs and earth header from LH
lower 'A' post.

HARNESSES
86-7-10 REPAIRS
90.Remove 4 screws from rear bumper lamps,
release lamps and disconnect multiplugs.
91.Release harness clips and pull harness into
luggage compartment.
92.Release main harness retaining clips and pull
harness into vehicle interior.
93.Remove main harness.Refit
1.Lay main harness in vehicle.
2.Locate rear section and secure in retaining
clips.
3.Feed harness to rear bumper lamps, secure in
clips and grommets.
4.Connect multiplugs to rear bumper lamps, fit
rear lamps and secure with screws.
5.Fit LH rear earth header and secure with nut.
6.Connect multiplugs to LH tail lamp.
7.Position RH tail lamp and connect multiplugs.
8.Fit RH tail lamp and secure with Torx screws.
9.Fit RH rear earth header and secure with nut.
10.Connect multiplug to towing electrics.
11.Connect rear screen washer tube.
12.Connect tail door harness multiplugs.
13.Connect and fit rear window lift and wash/wipe
relays.
14.Position harness into luggage compartment.
15.Connect both rear ABS speed sensor
multiplugs and secure harness grommets.
16.Connect multiplug to fuel pump.
17.Fit fuel pump access cover and secure with
screws.
18.Fit luggage compartment carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
19.Connect multiplugs at the base of 'B/C' Posts.
20.Fit all harness clips to interior of vehicle.
21.Fit multiplugs and earth header to LH lower 'A'
post.
22.Fit earth header to RH lower 'A' post.
23.Connect multiplug to window lift ECU.
24.Fit face level vent ducting.
25.Fit steering column to bracket and secure with
nuts.
26.Fit rear heater ducting and secure with nut.
27.Secure harness to rear heater ducting with
clips.
28.Position mounting bracket and secure relays.
29.Connect Lucar to handbrake switch.
30. Manual gearbox only: Connect multiplug to
gear lever hill descent switch.
31.Connect multiplug to accelerometer.
32. Automatic gearbox only: Connect multiplugs
to gear selector.
33.Connect heated oxygen sensor multiplug.
34.Fit earth header to floor tunnel and secure with
nut.
35.Fit earth lead to airbag ECU and secure with
bolt.
36.Connect multiplug to airbag ECU.
37.Connect multiplugs to brake light switch and
brake pedal position switch.
38.Connect multiplug to throttle position sensor.
39.Fit harness clip to steering column.
40.Connect multiplug to steering column switch.

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.