power steering LAND ROVER FREELANDER 2001 User Guide

MAINTENANCE
MAINTENANCE 10-3
KV6 – Petrol Engine – Under Bonnet
View
LHD shown, RHD similar - 03 Model Year illustrated
1Power steering reservoir
2Cooling system expansion tank filler cap
3Brake/Clutch fluid reservoir cap
4Engine Control Module box
5Engine compartment fusebox
6Battery
7Engine oil filler cap
8Engine oil dipstick
9Windscreen washer reservoir filler cap

MAINTENANCE
MAINTENANCE 10-17
PAS Fluid Level
Check/Top-up
1.Check Power Assisted Steering (PAS) fluid
level. Before topping up PAS fluid level, ensure
there are no leaks from the pump, hoses,
unions or steering rack.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Fluids.
Intermediate Reduction Drive - Non NAS
models
Check and Top-up Fluid
1.With vehicle on a ramp at a convenient working
height, carefully remove IRD level plug and
collect sealing washer.
2.Check oil level. Before topping up oil level,
check for visible signs of leakage. Pay
particular attention to drive shaft and prop shaft
oil seals.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
3.Refit level plug to IRD unit using a new sealing
washer.

MAINTENANCE
MAINTENANCE 10-29
Gear Change and Parking Pawl Engagement –
(Automatic only, normal driving conditions)
1.Select 'R' and check for smooth take up.
2.Select 'D' and check for smooth up-changes of
ratio from rest.
3.Slow down vehicle and check for smooth down-
changes of ratio.
4.Stop vehicle on a slope.
5.Select 'P' and release handbrake.
6.Check that vehicle does not move and that
selector does not slip out of 'P'.
7.Carry out a similar check with vehicle facing in
the opposite direction.
Steering
1.With vehicle stationary, turn steering from lock
to lock. Check for smooth operation and ensure
there is no undue noise from the power steering
pump or drive belt.
Suspension
1.Check for noise, irregularity in ride (e.g.
dampers) and wheel imbalance.
Foot brake
1.Check for pedal effort, travel, braking
efficiency, pulling and binding.
Handbrake
1.Apply handbrake firmly, check travel and
ratchet hold and release.
Instruments
1.Check for correct operation of all instruments
and warning devices where practical.
Body
1.Check for abnormal body noise.
Seat Belts
1.Check for operation of inertia reels.Road Test
1.Drive vehicle on a short road test. Check all
vehicle systems for correct operation. Pay
particular attention to:
lEngine noise
lGearbox noise
lSuspension noise
lBody noise
lBraking system operation
lGear selection
lEngine performance
2.Where possible, check for correct operation of
Hill Descent Control (HDC) system. This should
not be carried out if excessive journey time is
required.
3.After road test, carry out a final inspection of the
vehicle on vehicle ramps.
4.Check all underbonnet fluid levels and top-up if
necessary.

STEERING
ADJUSTMENTS 57-1
STEERING ADJUST ME NTS
Power assisted steering (PAS) system -
bleed
$% 57.15.02
Check
1.Switch off engine.
2.Check power steering fluid, if aerated, wait until
fluid is free from bubbles then top-up reservoir
to 'UPPER' level mark.
3.Fit reservoir filler cap.
Adjust
1.Clean PAS fluid reservoir around filler cap and
fluid level indicators.
2.Remove filler cap from reservoir and fill
reservoir to 'UPPER' mark with Dexron II D
power steering fluid. Fluid must always be
present in reservoir while bleeding.
3.Start engine and allow to run at idle for 10
seconds. Stop engine.
4.Top-up steering fluid reservoir.
5.Start engine and turn steering fully to LH and
RH locks. Stop engine.
CAUTION: Do not hold steering at full lock
for longer than 10 seconds.
6.Top-up steering fluid reservoir.
7.Start and run engine for 2 minutes, turn
steering fully to RH and LH locks.
Cable - key interlock - adjust
$% 57.40.52
Check
1.Select position 'P'.
2.Remove key from starter switch.
3.Check that selector lever cannot be moved
from 'P' position.
4.Insert and turn key to position II.
5.Depress brake pedal and check that selector
lever can be moved from 'P' position, and key
cannot be removed from starter switch. Key
should only rotate back to a position between I
and 0.
Adjust
1.Select position 'P'.
2.Remove key from starter switch.
3.Remove front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
4.Loosen bolt securing cable clamp.
5.Pull cable away from interlock mechanism until
spring pressure is felt. Correct adjustment is
cable free play removed without compressing
spring. When correct tighten interlock cable
clamp screw to 6 Nm (4.5 lbf.ft).
6.Recheck cable operation.
7.Fit front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.

STEERING
57-4 ADJUSTMENTS
Power steering - pressure test
$% 57.90.10.01
Check
1.Position absorbent cloth to catch spillage.
2.Remove bolt securing PAS high pressure pipe
clip to PAS pump.
3.Loosen union securing high pressure pipe to
PAS pump and release pipe.
4. K1.8 models: Fit adaptor LRT-57-034A to high
pressure port of PAS pump.
5. KV6 & Td4 models: Fit adaptor LRT-57-042 to
high pressure port of PAS pump.
6.Fit adaptor LRT-57-035 to existing high
pressure hose.
7.Fit hose LRT-57-002 to each adaptor.
8.Fit pressure gauge LRT-57-005 to test valve
LRT-57-001
9.Connect hoses LRT-57-002 to LRT-57-001
and tighten unions.
10.Ensure steering system and test equipment is
free from leaks.
11.Maintain maximum fluid level during test.
12.With the test valve open, start the engine.
13.Pressure at idle should be between 5 and 7
bar.
14.With the engine at idle, slowly turn the steering
wheel and hold on full lock.
15.Repeat procedure for other side.
16.Test pressure should rise significantly as
steering wheel is rotated and continue to rise as
full lock is approached. For full lock pressures,
refer to general data section.

+ GENERAL DATA, Steering.
17.With the engine at idle, release steering wheel.
For idle pressure, refer to general data section.

+ GENERAL DATA, Steering.
18.Pressures outside the above tolerance
indicates a fault.19.To determine if fault is in steering pump or
steering rack, close the test valve for a
maximum of 5 seconds.
CAUTION: Pump damage will occur if test
valve is closed for longer periods.
20.If gauge does not register correct reading,
suspect faulty pump.
21.If PAS pump pressure is correct and steering is
heavy at idle and becomes light as engine RPM
is increased, suspect pump flow rate.
22.If maximum pump pressure is correct, suspect
steering rack.
23.On completion stop engine and remove test
equipment.
24.Clean PAS pump and pipe union.
25.Fit new 'O' ring to high pressure pipe, align to
PAS pump and tighten union to 25 Nm (18
lbf.ft).
26.Fit bolt securing high pressure pipe clip and
tighten to 8 Nm (6 lbf.ft).
27.Check and top-up PAS fluid level.

+ MAINTENANCE, MAINTENANCE,
Intermediate Reduction Drive - Non NAS
models.

STEERING
REPAIRS 57-5
REPAIRS
Power steering rack
$% 57.10.01
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 front road wheels.
3.Remove and discard nuts securing track rod
ball joints to steering arms.
4.Fit an M12 nut to each ball pin, flush with end of
each pin.
5.Using LRT-57-043, separate ball pins from RH
and LH steering arms. Remove M12 nuts and
release ball pins from steering arms.
6.Remove pinch bolt securing steering column to
PAS rack pinion.7. KV6 models: Remove 2 nuts securing steering
rack heat shield and remove heat shield.
8. KV6 models: Remove 2 bolts securing coolant
rail to cylinder block.
9. Td4 manual models: Using tool LRT-37-050
release gear change rods from gear change
linkage.
10. Td4 manual models: Remove 2 bolts securing
gearchange linkage to bulkhead and tie aside.

STEERING
REPAIRS 57-7
25.Remove dust seal from pinion housing.
Refit
1.Fit PAS rack to vehicle from passengers side.
2.Fit dust shield to pinion housing.
3. KV6 models: Fit RH Hydramount.

+ ENGINE - K SERIES KV6, REPAIRS,
Hydramount - engine - RH.
4.Ensure pipe unions are clean.
5.Fit new 'O' rings to fluid pipes.
6.Fit fluid pipes to PAS rack but do not tighten at
this stage.
7.Align fluid pipe bracket to PAS rack, fit bolt but
do not tighten at this stage.
8.With assistance fit PAS rack pinion to steering
column, ensuring column coupling is aligned
with gear input flag.
9.Fit washers and new bolts securing steering
rack mounting to bulkhead, but do not tighten at
this stage. Ensure large washer is fitted to lower
bolt.
10.Fit rubber mount and clamp to PAS rack.
11.Fit bolts securing clamp to bulkhead but do not
tighten at this stage.
12.Tighten PAS rack mounting bolts to 45 Nm (33
lbf.ft).
13.Tighten PAS rack clamp bolts to 45 Nm (33
lbf.ft).
14.Tighten PAS rack fluid feed pipe union to 18
Nm (13 lbf.ft).
15.Tighten PAS rack fluid return pipe union to 22
Nm (16 lbf.ft).
16.Tighten fluid pipe bracket to 10 Nm (7 lbf.ft).
17.Align PAS rack clamp and tighten bolt.
18.Align pipes to clamp fit bolt and tighten to 10
Nm (7 lbf.ft).
19.Fit pinch bolt to steering column and tighten to
32 Nm (24 lbf.ft).
CAUTION: Nuts and bolts must be tightened
with the weight of the vehicle on the
suspension.20.Ensure tapers in track rod end and steering arm
are clean and rubber boot is not damaged.
21.Fit ball joints to steering arms, fit new nuts and
tighten to 55 Nm (40 lbf.ft).
22. KV6 models: Align coolant rail to cylinder
block, fit bolts and tighten to 10 Nm (7 lbf.ft).
23. KV6 models: Position heat shield, fit nuts and
tighten to 25 Nm (18 lbf.ft)
24. Td4 manual models: Align IRD hose 'P' clip fit
bolt and tighten to 25 Nm (18 lbf.ft).
25. Td4 manual models: Align gearchange
linkage to bulkhead, fit bolts and tighten to 25
Nm (18 lbf.ft).
26. Td4 manual models: Connect gear change
rods to gear change linkage.
27. Td4 auto models:Align IRD hose 'P' clip fit bolt
and tighten to 25 Nm (18 lbf.ft).
28.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
29.Remove stands and lower vehicle.
30.Bleed PAS system.

+ STEERING, ADJUSTMENTS, Power
assisted steering (PAS) system - bleed.
31.Check and adjust front wheel alignment.

+ STEERING, ADJUSTMENTS, Front
wheel alignment - check & adjust.

STEERING
57-8 REPAIRS
Gaiter - PAS rack
$% 57.10.29
Remove
1.Remove PAS rack.

+ STEERING, REPAIRS, Power
steering rack.
2.Hold PAS rack securely and remove 2 Torx
bolts securing track rods. Discard bolts.
3.Remove support plate.
4.Remove track rods and spacers.
CAUTION: Note orientation of spacers
before dismantling.
5.Remove clips from PAS rack ram feed pipes.
6.Loosen 4 pipe unions and remove both ram
feed pipes.
CAUTION: Always fit plugs to open
connections to prevent contamination.
7.Remove clamp bolt from fluid pipe support
bracket and remove bracket.
8.Remove 2 gaiter securing clips.9.Remove gaiter sealing ring.
10.Remove gaiter.
11.Remove gaiter sealing band.
12.Remove slider and clip assembly.
13.Remove clip from slider.
Refit
1.Clean remains of lubricant from PAS rack slider
and clip.
2.Fit clip to slider and fit slider assembly to PAS
rack.
3.Apply grease supplied in the gaiter kit to
exposed rack shaft, slider and clip.
4.Fit gaiter sealing band.
5.Fit gaiter.
6.Fit gaiter sealing ring.
7.Align gaiter to slider and having ensured slider
is correctly located, use track rod securing bolts
to hold gaiter in position, without tightening
bolts, so to activate Loctite.
CAUTION: Do not screw bolts in more than
4 or 5 turns.
8.Ensure gaiter is not twisted, and fit gaiter
securing clips.
9.Fit fluid pipe support bracket and secure with
bolt.
10.Ensure pipe unions and rack ports are clean.
11.Fit both ram feed pipes and tighten small
diameter pipe to 18 Nm (13 lbf.ft)and large
diameter pipe to 24 Nm (18 lbf.ft).
12.Fit clips to pipes.
13.Remove track rod bolts securing bolts used to
align gaiter, fit spacers, track rods and support
plate to PAS rack.
CAUTION: Ensure spacers are aligned and
fitted correctly.
14.Hold track rods parallel with PAS rack and
tighten new Torx bolts to 100 Nm (74 lbf.ft).
15.Fit PAS rack.

+ STEERING, REPAIRS, Power
steering rack.

STEERING
57-10 REPAIRS
14.Remove clips from PAS oil cooler.
Refit
1.Clean cooler mounting points.
2.Fit clips to PAS cooler.
3.Fit PAS oil cooler to vehicle.
4.Connect quick release pipe fitting.
5.Align PAS pipe bracket, fit bolt and tighten to 10
Nm (7 lbf.ft).
6.Fit bolt to clip securing PAS pipe to RH turret,
tighten to 10 Nm (7 lbf.ft).
7.Fit PAS reservoir to mounting bracket.
8.Clean PAS fluid reservoir around filler cap and
fluid level indicators.
9.Fit PAS return hose to reservoir and secure
clip.
10. Td4 models: Fit intercooler outlet hose and
tighten clips.
11. Td4 models: Fit intake duct to body and duct
assembly.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Ducting - intake assembly.
12. Td4 models: Fit engine oil dipstick.
13. Fit engine acoustic cover if fitted.

+ ENGINE - Td4, REPAIRS, Cover -
engine acoustic - Up to 02.5 Model Year.
14.Connect battery earth lead.
15.Bleed PAS system.

+ STEERING, ADJUSTMENTS, Power
assisted steering (PAS) system - bleed.
Oil cooler - KV6 models
$% 57.15.11
Remove
1.Remove front bumper.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
2.Position container below PAS pipes to catch
fluid spillage.
3.Using LRT-57-044 release and disconnect
PAS hoses from oil cooler.
4.Remove 2 bolts and remove PAS fluid cooler.
Refit
1.Fit fluid cooler and tighten bolts to 10 Nm (7
lbf.ft).
2.Clean connections.
3.Connect hoses to fluid cooler.
4.Fit front bumper.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5.Bleed PAS system.

+ STEERING, ADJUSTMENTS, Power
assisted steering (PAS) system - bleed.
M57 1204
LRT-57-044

STEERING
REPAIRS 57-13
10.Remove 3 bolts securing PAS pump to
mounting bracket.
11.Remove PAS pump.Refit
1.Position PAS pump and align to mounting
bracket.
2.Fit bolts securing PAS pump to mounting
bracket and tighten to 25 Nm (18 lbf.ft).
3.Fit PAS pump pulley to PAS pump and tighten
bolts to finger tight.
4.Remove plug from fluid outlet hose.
5.Clean banjo bolt and mating faces.
6.Using new sealing washers, fit PAS outlet hose
to pump and tighten banjo bolt to 20 Nm (15
lbf.ft).
CAUTION: To prevent damage to
components, use two spanners when
loosening or tightening unions.
7.Align outlet pipe clip. Fit bolt and tighten to 22
Nm (16 lbf.ft).
8.Clean elbow on PAS pump.
9.Remove plug from fluid inlet hose, fit new clip
and connect hose to PAS pump.
10.Remove container.
11.Clean pulley 'V's and tensioner pulley running
surface.
12.Using a 3/8” square drive socket bar, raise
ancillary drive belt tensioner and fit drive belt to
pulleys.
13.Tighten PAS pump pulley bolts to 10 Nm (7.5
lbf.ft).
14.Fit engine mounting top arm.

+ ENGINE - K SERIES KV6, REPAIRS,
Arm assembly - engine mounting RH.
15.Connect battery earth lead.
16.Bleed PAS system.

+ STEERING, ADJUSTMENTS, Power
assisted steering (PAS) system - bleed.