ECU LAND ROVER FREELANDER 2001 Workshop Manual

REAR AXLE & FINAL DRIVE
51-2 REPAIRS
Refit
1.With assistance position differential assembly
to subframe and locate in mountings, fit bolts
but do not tighten at this stage.
2.Position centralising jig LRT-51-013 to align
differential assembly.
3.Tighten forward bolts to 65 Nm (48 lbf.ft).
4.Tighten rearward bolts to 65 Nm (48 lbf.ft).
5.Remove LRT-51-013.
6.Connect breather pipe.
7.Position propeller shaft to rear axle and align
reference marks.
8.Fit and tighten nuts and bolt securing propeller
shaft to rear axle to 65 Nm (48 lbf.ft).
9.Fit drive shafts.

+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - LH.

+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - RH.
10.Check differential oil level.

+ MAINTENANCE, MAINTENANCE,
Rear Axle.
Cover - rear - differential
$% 51.15.04
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.Position container to catch oil spillage.
3.Remove oil level plug.
4.Remove 10 bolts securing rear cover to
differential casing.
5.Remove rear cover.
Refit
1.Clean rear cover, mating face on differential
and sealant from bolts and bolt threads.
2.Apply sealant, Part No. STC 3811 to casing
and fit rear cover.
3.Apply sealant, Part No. STC 50552 to threads
of rear cover bolts.
4.Fit rear cover bolts bolts and tighten by
diagonal selection to 25 Nm (18 lbf.ft).
5.Fill differential with oil.

+ MAINTENANCE, MAINTENANCE,
Rear Axle.
6.Fit level plug and tighten to 27 Nm (20 lbf.ft).
7.Remove stands and lower vehicle.

REAR AXLE & FINAL DRIVE
REPAIRS 51-3
Bush - differential mounting - front
$% 51.15.43
Remove
1.Remove LH mounting.

+ REAR AXLE & FINAL DRIVE,
REPAIRS, Bush - differential mounting -
rear.
2.Remove 2 bolts securing RH mounting to
differential.
3.Remove 2 bolts securing front mounting to
differential.
4.Remove bolt securing front mounting
subframe.
5.Ease differential away from front mounting and
remove front mounting.Refit
1.Ease differential away from front mounting and
fit front mounting.
2.Ensure differential is correctly located in LRT-
51-013.
3.Fit bolt securing mounting to subframe and
tighten to 120 Nm (89 lbf.ft).
4.Fit bolts securing front mounting to differential
and tighten to 65 Nm (48 lbf.ft).
5.Tighten RH mounting bolts to 65 Nm (48 lbf.ft).
6.Fit LH mounting.

+ REAR AXLE & FINAL DRIVE,
REPAIRS, Bush - differential mounting -
rear.

REAR AXLE & FINAL DRIVE
51-4 REPAIRS
Bush - differential mounting - rear
$% 51.15.44
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.Position centralising jig LRT-51-013 to align
differential assembly.
3.Remove bolt securing differential mounting to
subframe.
4.Remove 2 bolts securing mounting to
differential.
5.Remove mounting.Refit
1.Position differential mounting.
2.Fit bolts securing mounting to differential and
tighten to 65 Nm (48 lbf.ft).
3.Fit bolt securing mounting to subframe and
tighten to 120 Nm (89 lbf.ft).
4.Remove LRT-51-013.
5.Remove stands and lower vehicle.

REAR AXLE & FINAL DRIVE
REPAIRS 51-5
Oil seal - pinion
$% 51.20.01
Remove
1.Release both drive shafts from differential
assembly.

+ REAR AXLE & FINAL DRIVE,
REPAIRS, Oil seal - differential housing.
2.Reference mark propeller shaft and pinion
flanges to aid reassembly.
3.Remove 4 nuts and bolts securing propeller
shaft to differential. Release propeller shaft and
tie aside.
4.Check and record the torque required to rotate
the pinion and differential.
CAUTION: Drive shafts must be removed to
obtain correct torque to turn figure.
5.Using LRT-51-003 to restrain differential
flange, remove nut and washer securing pinion
flange. Discard nut.6.Remove pinion flange.
7.Carefully remove and discard oil seal, take care
not to damage oil seal recess.
8.Remove oil thrower.
9.Remove pinion bearing inner race.
10.Remove and discard collapsible spacer.

REAR AXLE & FINAL DRIVE
51-6 REPAIRS
Refit
1.Fit new collapsible spacer.
2.Fit pinion bearing and oil thrower.
3.Clean pinion flange and oil seal recess.
4.Fit new oil seal using LRT-51-010.
5.Fit pinion flange and washer.
6.Restrain pinion flange using LRT- 51-003.
7.Fit new pinion nut and tighten to 190 Nm (140
lbf.ft).
8.Check for end float on pinion. If end float exists
continue to tighten pinion nut until end float is
removed.
9.Continue to tighten pinion nut until correct
preload is obtained.
10.Pinion preload is 1.7 - 2.8 Nm (1.2 - 2.1 lbf.ft), if
higher replace collapsible spacer.
CAUTION: Do not tighten pinion nut to more
than 373 Nm (275 lbf.ft), or the collapsible
spacer will compress too far.
11.Clean propeller shaft flange and mating face.
12.Position propeller shaft to rear axle and align
reference marks.
13.Tighten propeller shaft nuts and bolts to 65 Nm
(48 lbf.ft).
14.Fit drive shafts.

+ REAR AXLE & FINAL DRIVE,
REPAIRS, Oil seal - differential housing.
15.Check differential oil level.

+ MAINTENANCE, MAINTENANCE,
Rear Axle.
Oil seal - differential housing
$% 51.20.36
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.Remove bolt securing handbrake cable to
subframe.
4.Remove nut and bolt securing trailing link to
rear hub, collect spacer from under bolt head.
5.Remove nut and bolt securing fixed transverse
link to subframe. Collect dynamic damper.
6.Remove nut and bolt securing adjustable
transverse link to subframe.
7.Position drain tin to catch oil spillage.
8.With assistance pull hub assembly outwards.

REAR AXLE & FINAL DRIVE
REPAIRS 51-7
9.Taking care not damage oil seal 'flinger',
release drive shaft from differential using LRT-
51-014 and position shaft aside.
10.Remove and discard circlip from drive shaft.
11.Remove differential oil seal.Refit
1.Clean drive shaft oil seal recess in axle casing.
2.Fit new oil seal using LRT-51-012.
3.Clean end of drive shaft and location in
differential.
4.Check condition of oil seal 'Flinger', renew if
damaged.
5.Fit new circlip to drive shaft.
6.With assistance fit drive shaft to differential,
push drive shaft fully home to engage circlip.
7.Fit nut and bolt to fixed transverse link and
tighten to 120 Nm (89 lbf.ft).
CAUTION: Nuts and bolts must be tightened
with weight of vehicle on suspension.
8.Fit nut, bolt and dynamic damper to adjustable
transverse link and tighten to 120 Nm (89 lbf.ft).
9.Fit spacer, nut and bolt to trailing link and
tighten to 120 Nm (89 lbf.ft).
10.Fit bolt securing handbrake cable clip and
tighten to 22 Nm (16 lbf.ft).
11.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
12.Check differential oil level.

+ MAINTENANCE, MAINTENANCE,
Rear Axle.
13.Remove stands and lower vehicle.

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
57-6 REPAIRS
11. Td4 manual models: Remove bolt securing
IRD coolant hose 'P' clip.
12. Td4 auto models: Remove bolt securing IRD
coolant hose 'P' clip.
13.Remove 2 bolts and washers securing PAS
rack clamp to bulkhead, discard bolts.
14.Remove PAS rack clamp.
15.Remove rubber mount.16.Remove and discard 2 bolts securing PAS rack
mounting to bulkhead.
17.Release PAS rack pinion from steering column.
18.Position container to collect PAS fluid spillage.
19.Remove bolt securing pipe bracket to PAS
rack.
20.Release pipe unions and disconnect fluid pipes
from PAS rack.
CAUTION: Always fit plugs to open
connections to prevent contamination.
21.Remove and discard 'O' rings.
22.Remove bolt securing PAS pipes to clamp and
loosen clamp bolt.
23. KV6 models: Remove RH Hydramount and
lower engine to aid rack removal.

+ ENGINE - K SERIES KV6, REPAIRS,
Hydramount - engine - RH.
24.With assistance remove PAS rack from
passenger side of vehicle.

M57 1071