heater LAND ROVER FREELANDER 2001 User Guide

ENGINE - K SERIES KV6
12-3-44 REPAIRS
35.Fit rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
36.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
37.Fit exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - NAS.
38.With assistant depressing the brake pedal,
tighten front hub nuts to 400 Nm.
39.Stake nuts to drive shafts
40.Fit front road wheels, fit and tighten nuts to 115
Nm.
41.Lower vehicle on lift.
42.Connect brake servo vacuum hose to inlet
manifold chamber.
43.Connect coolant hose to underside of
expansion tank and secure with clip.
44.Connect expansion tank hose to inlet manifold
and secure clip.
45.Connect top hose to radiator and secure with
clip. Position hose in bracket.
46.Connect heater feed and return hoses and
secure with clips.
47.Connect throttle inner cable to throttle cam and
secure outer cable in abutment bracket.
48.Connect hose to purge valve.
49.Fit purge hose into clip.
50.Connect fuel hose to fuel rail pipe, fit rubber
sleeve over hose connector.
51.Connect gearbox harness multiplugs and
secure multiplugs in mounting bracket clips.
52.Connect Lucar connector to starter solenoid.
53.Position earth lead to gearbox housing, fit and
tighten bolt to 25 Nm.
54.Position engine harness to 'E' box mounting
bracket and secure with clips.
55.Connect earth header multiplug.
56.Connect multiplug to under bonnet fuse box.
57.Position battery and starter motor lead to under
bonnet fuse box, fit and tighten bolts to 8 Nm.
58.Fit under bonnet fuse box cover.
59.Position 'E' box, secure in retaining clip, fit and
tighten nut to 9 Nm.
60.Fit carrier to 'E' box.
61.Fit air ducting to 'E' box.
62.Fit body harness to 'E' box, secure grommet
and harness clip.
63.Connect 'E' box cooling fan multiplug.
64.Connect multiplug to 'E' box temperature
sensor.
65.Connect multiplug to gearbox ECU.
66.Position engine harness to 'E' box and secure
grommet.67.Fit engine harness clamp and secure with
screws.
68.Connect engine harness multiplug to body
harness multiplug and fit multiplug to 'E' box.
69.Fit heated front screen harness to battery
positive cable and tighten bolt to 15 Nm (11
lbf.ft).
70.Fit engine ECM.

+ ENGINE MANAGEMENT SYSTEM -
SIEMENS, REPAIRS, Engine control module
(ECM) - fuel - NAS.
71.Fit battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
72.Fill cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
73.Connect the battery earth lead.
74.Fill gearbox with fluid.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
75.Fit the engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
76.Untie and close bonnet.

FUEL DELIVERY SYSTEM - PETROL
REPAIRS 19-2-41
Vacuum pump - cruise control - KV6 -
non NAS
$% 19.75.06
Remove
1.Remove battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
2.Release 3 rubber mountings securing vacuum
pump to battery carrier and remove vacuum
pump.
3.Remove 3 rubber mountings from vacuum
pump.
Refit
1.Fit rubber mountings to vacuum pump.
2.Position vacuum pump to battery carrier and
secure with rubber mountings.
3.Fit battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
Switch - cruise control - KV6 - up to 04MY
$% 19.75.30
Remove
1.Remove radio.

+ IN CAR ENTERTAINMENT,
REPAIRS, Radio - up to 04MY.
2.Remove selector knobs from heater controls.
3.Remove 2 screws securing heater control
finisher to heater controls and remove finisher.
4.Release cruise control switch, disconnect
multiplug and remove switch.
Refit
1.Position cruise control switch, connect
multiplug and secure switch.
2.Fit heater control finisher to heater controls and
secure with screws.
3.Fit heater control knobs.
4.Fit radio.

+ IN CAR ENTERTAINMENT,
REPAIRS, Radio - up to 04MY.

COOLING SYSTEM - K SERIES KV6
ADJUSTMENTS 26-3-1
COOLING SYS TEM - K SER IES KV6 ADJUST ME NTS
Coolant - drain and refill
$% 26.10.01
Drain
1.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
2.Visually check engine and cooling system for
signs of coolant leaks.
WARNING: Since injury such as scalding
could be caused by escaping steam or
coolant, do not remove the filler cap from
the coolant expansion tank while the
system is hot.
3.Examine hoses for signs of cracking, distortion
and security of connections.
4.Remove expansion tank filler cap.
5.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
6.Position container to collect coolant.
7.Remove cylinder block drain plug.
8.Release clip and remove bottom hose from
radiator.
9.Allow cooling system to drain.Refill
1.Flush system with water under low pressure.
Do not use water under high pressure as it
could damage the radiator.
2.Clean cylinder block drain plug and apply
sealant, Part No. STC 50552 to first 3 threads.
3.Fit cylinder block drain plug and tighten to 20
Nm (15 lbf.ft).
4.Fit bottom hose to radiator and secure with clip.
5.Prepare coolant to required concentration.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Fluids.
6.Remove bleed screw from heater return hose.
7.Slowly fill the system through the coolant
expansion tank until a steady flow of coolant is
emitted from the bleed hole.
8.Fit and close bleed screw in heater return hose.
9.Continue to fill system through the expansion
tank until coolant reaches to the base of the
expansion tank bleed hose.
10.Fit expansion tank filler cap.
11.Start and run engine at idle speed for 5
minutes.
CAUTION: DO NOT operate air conditioning
12.Switch off engine.
13.Squeeze bottom hose several times to remove
any trapped air.
14.Start engine and run at speeds varying
between idle speed and 3500 rev/min for 7
minutes.
15.Switch off engine and allow to cool.
16.Remove expansion tank filler cap and add
coolant until it reaches the 'MAX' mark on the
expansion tank.
17.Fit expansion tank filler cap.
18.Start and run engine until normal operating
temperature is reached.
CAUTION: The bottom hose must be warm/
hot, this will ensure the thermostat is fully
open.

COOLING SYSTEM - K SERIES KV6
26-3-2 ADJUSTMENTS
19.Ensure warm air is available at vents.
NOTE: If warm air is not available, an air-lock
may be present in heater matrix. If necessary,
allow engine to cool, remove expansion tank
filler cap and repeat bleed operation at heater
hose
20.Switch off engine and allow to cool.
21.Check for leaks and top-up coolant to 'MAX'
mark on expansion tank
22.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
23.Fit engine acoustic cover.

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

COOLING SYSTEM - K SERIES KV6
26-3-6 REPAIRS
Thermostat
$% 26.45.01
Remove
1.Disconnect battery earth lead.
2.Drain cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
3.Remove inlet manifold chamber.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.
4.Remove 2 bolts securing RH fuel rail to inlet
manifold. Remove injector protection cover if
fitted.
5.Release 2 clips securing engine harness to rear
engine lifting bracket and bracket on RH inlet
manifold.
6.Release clip and disconnect bottom hose from
thermostat housing.
7.Loosen clip and disconnect heater hose from
thermostat housing.8.Release clip and disconnect top hose from
coolant elbow.
9.Remove bolt securing thermostat housing and
coolant elbow to cylinder block.
10.Remove coolant elbow from cylinder block.
11.Remove thermostat housing and coolant pipe
from cylinder block.
12.Release clip and remove coolant pipe from
thermostat housing.
13.Remove and discard 4 'O' rings from
thermostat housing, coolant elbow and coolant
pipe.
Refit
1.Lubricate new 'O' rings with rubber grease and
fit to sealing grooves in thermostat housing,
coolant elbow and coolant pipe.
2.Fit coolant pipe into thermostat housing, ensure
clip connectors are uppermost.
3.Position thermostat housing and coolant pipe
above cylinder block, engage coolant pipe in
cylinder block and press thermostat housing
firmly into position. Ensure mounting flange on
thermostat housing is aligned to bolt hole in
cylinder block.
4.Fit coolant elbow into cylinder block, press
firmly into place. Ensure mounting flange is
aligned correctly to thermostat housing flange.
5.Fit bolt to coolant elbow and thermostat
housing flanges. Tighten bolt to 18 Nm (13
lbf.ft).
6.Connect top hose to coolant elbow and secure
with clip.
7.Connect heater and bottom hoses to
thermostat housing, secure with clips.
8.Position and secure engine harness to brackets
with clips.
9.If fitted, position injector protection cover to RH
fuel rail, fit and tighten bolts to 9 Nm (7 lbf.ft).
10.Fit inlet manifold chamber.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Seals - inlet
manifold chamber - up to 03MY.
11.Fill cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
12.Connect battery earth lead.

STEERING
57-18 REPAIRS
Cable - key interlock
$% 57.40.51
Remove
1.Disconnect battery earth lead.
2.Remove front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
3.Loosen bolt securing cable clamp.
4.Disconnect cable from interlock mechanism.
5.Remove key from starter switch.
6.Remove steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
column.
7.Remove bolt securing steering column height
adjuster lever and remove lever.
NOTE: Thread is left handed.
8.Remove nut securing height adjuster clamp
bolt and remove bolt.
9.Collect plastic stop.10.Loosen union and disconnect cable from
column lock.
11.Release cable from 2 retaining clips.
12.Note the cable routing, manoeuvre cable from
under heater and steering column bracket.
13.Remove cable.

STEERING
REPAIRS 57-19
Refit
1.Position cable, align to heater and steering
column bracket and secure in retaining clips.
2.Align key interlock cable to column lock and
tighten union to 4 Nm (3 lbf.ft).
3.Fit height adjuster clamp bolt and tighten nut to
10 Nm (7.5 lbf.ft). Ensure bolt and plastic stop
are correctly located in slot in column bracket.
4.Fit height adjuster lever and tighten bolt 12 Nm
(9 lbf.ft). Ensure lever is in the fully up position
before tightening bolt. Hold clamp bolt nut to
prevent nut rotation.
5.Connect cable to interlock mechanism.
6.Check key interlock cable adjustment.

+ STEERING, ADJUSTMENTS, Cable
- key interlock - adjust.
7.Fit steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
column.
8.Fit front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
9.Connect battery earth lead.
Column assembly - inner & outer
$% 57.41.01
Remove
1.Disconnect battery earth lead.
2.Remove steering column multi purpose switch.

+ LIGHTING, REPAIRS, Switch -
combined direction indicator/headlight/
horn.
3.Disconnect multiplugs from ignition switch and
passive coil.
4.Remove 2 screws securing steering column
aperture trim and remove trim.

RESTRAINT SYSTEMS
75-16 REPAIRS
8.Disconnect SRS connector from airbag
module.
9.Remove airbag module.
WARNING: Store the airbag module with the
deployment side uppermost. If it is stored
deployment side down, accidental
deployment will propel the airbag module
with enough force to cause serious injury.
Refit
1.Position airbag module and connect SRS
connector to airbag module.
NOTE: If the airbag module is to be replaced,
the bar code of the new module must be
recorded.
2.Fit airbag to fascia and tighten Torx screws to
10 Nm (7 lbf.ft).
3.Align lower finisher to bracket.
4.Fit 4 screws securing lower finisher bracket.
5.Fit and secure lower finisher clips
6.Fit 2 screws securing airbag module to fascia.
7.Connect battery leads, earth lead last.
Diagnostic control unit (DCU)
$% 76.74.06
Remove
WARNING: It is imperative that before any
work is undertaken on the SRS system the
appropriate information is read thoroughly.
1.Make the SRS system safe.

+ GENERAL INFORMATION,
Supplementary restraint system
precautions.
2.Remove heater assembly.

+ HEATING AND VENTILATION,
REPAIRS, Heater unit.
3.Disconnect multiplug from DCU.
4.Remove 3 Torx bolts securing DCU to body and
remove DCU. Discard Torx bolts.
Refit
1.Fit DCU to body and secure with new bolts.
Tighten bolts to 9 Nm (7 lbf.ft).
2.Connect multiplug to DCU.
3.Fit heater assembly.

+ HEATING AND VENTILATION,
REPAIRS, Heater unit.
4.Connect battery leads, earth lead last.

DOORS
76-1-8 REPAIRS
Rubber/felt - glass channel - front door
$% 76.31.13
Remove
1.Remove exterior mirror.

+ EXTERIOR FITTINGS, REPAIRS,
Mirror - exterior - electric.
2.Lower door glass.
3.Remove inner seal.
4.Carefully release seal from door flange, starting
from the cheater panel, working along the waist
rail and around the door flange.Refit
1.Lubricate corners of seal with soapy water.
CAUTION: This seal assembly uses an
internal metal former. Take care not to bend
the seal during fitment, or the former will
become kinked.
2.Starting at the rearmost top corner of the glass
aperture, seat the seal onto the flange,
ensuring that the radius of the seal matches the
door profile.
3.Secure seal to flange across cantrail and down
'A' post.
4.Secure seal in corner at base of 'A' post.
5.Carefully pull 'B' post length of seal away from
flange until bottom corner is just clear of flange,
seal will then locate over flange. Ensure seal
has not become twisted. Starting from the top,
push the seal onto the flange.
NOTE: The bottom radius should match the
door profile.
6.Secure the seal to the bottom flange by rotating
the seal onto the flange and pushing evenly on
its length along the waist rail.
7.Fit inner seal.
8.Raise and lower glass to check seal fit.
9.Fit exterior mirror.

+ EXTERIOR FITTINGS, REPAIRS,
Mirror - exterior - electric.

DOORS
76-1-10 REPAIRS
Glass - tail door
$% 76.31.20
Remove
1.Remove tail door plastic sheet.

+ DOORS, REPAIRS, Plastic sheet -
tail door.
2.Disconnect 2 Lucars from heater element.
3.Lower screen to access clamp bolts.
4.Loosen both clamp bolts, release and remove
rear screen.Refit
1.Position screen to door and align in clamps
using timing marks on screen.
2.Ensure glass is fully pushed down in clamp
closest to door hinge, then tighten clamp bolt.
3.Position screen horizontally by lifting clamp
closest to door latch so that screen heater
element is aligned with waist seal.
4.Tighten clamp bolts to 8 Nm (6 lbf.ft).
5.Raise screen and connect Lucars to screen
heater element.
6.Ensure a 5mm equal gap exists between
screen and both 'E' post finishers. If required,
adjust screen again using timing marks.
7.Loosen lower adjuster lock nuts.
8.Loosen pre-load screws so screen clears seal.
9.Adjust pre-load screws until screen is just in
contact with seal.
10.Adjust pre-load screws until screen applies a
1mm pre-load on seal.
11.Ensure there is full screen to seal contact.
12.Lower glass and tighten lock nuts to 14 Nm (10
lbf.ft).
13.Recheck pre-load.
14.Raise and lower screen to confirm correct
alignment.
15.Fit tail door plastic sheet.

+ DOORS, REPAIRS, Plastic sheet -
tail door.