bonnet LAND ROVER FREELANDER 2001 Owner's Manual

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-17
21.Position access plate, fit bolts and tighten to 9
Nm (7 lbf.ft).
22.Clean mating faces of IRD and gearbox.
23.Lubricate and fit new 'O' ring.
24.With assistance, fit IRD.
25.Fit bolts securing IRD to gearbox and tighten
sufficiently only to pull mating faces of IRD and
gearbox together at this stage.
26.Fit IRD support bracket and tighten bolts
sufficiently only to pull mating faces together.
27.Final tighten bolts securing IRD to gearbox to
80 Nm (59 lbf.ft).
28.Final tighten bolts securing IRD support
bracket in following sequence:5 bolts securing
support bracket to IRD 50 Nm (37 lbf.ft), 2 bolts
securing support bracket to engine front
mounting bracket 50 Nm (37 lbf.ft), 3 bolts
securing support bracket to sump 45 Nm (33
lbf.ft).
29.Position lower engine steady, 'TOP' mark
uppermost. Fit bolt but do not tighten at this
stage.
30.Connect coolant hoses and secure with clips.
31.Connect breather hose to IRD housing.
32.Fit manifold heat shield and fit nut securing
heat shield to pinion housing finger tight.
33.Fit bolts securing manifold heat shield to IRD
support bracket and tighten to 9 Nm (7 lbf.ft).
34.Fit nut securing heat shield to IRD and tighten
to 45 Nm (33 lbf.ft).
35.Final tighten nut securing manifold heat shield
to IRD pinion housing to 25 Nm (18 lbf.ft).
36.Clean exhaust manifold and mating face on
cylinder head.
37.Fit exhaust manifold gasket.
38.Position exhaust manifold, fit nuts and
progressively tighten, from centre outwards to
45 Nm (33 lbf.ft).
39.Connect HO2S multiplug and secure to support
bracket.
Gearbox - KV6
$% 44.20.02.99
Remove
1.Tie bonnet back in upright position.
2.Disconnect battery earth lead.
3.Remove engine acoustic cover.

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

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.
5.Loosen selector cable trunnion nut.
6.Release clip securing selector cable to gearbox
bracket, remove selector cable and collect
trunnion from selector lever.
7.Remove 3 screws securing LH splash shield
and remove shield.

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-23
23.Fit CKP sensor, fit bolt and tighten to 9 Nm (7
lbf.ft).
24.Position fluid cooler, tighten M12 bolts to 85 Nm
(63 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).
25.Clean fluid cooler unions.
26.Lubricate new 'O' rings with clean transmission
fluid and fit 'O' rings to fluid cooler hoses.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
27.Connect fluid cooler hoses to gearbox and
tighten unions to 18 Nm (13 lbf.ft).
28.Clean exhaust manifold and mating face on
cylinder head.
29.Fit exhaust manifold gasket.
30.Position exhaust manifold, fit nuts and
progressively tighten, from centre outwards to
45 Nm (33 lbf.ft).
31.Connect HO2S multiplug and secure to support
bracket.
32.Position IRD cooling hose retainer, fit bolt and
tighten to 25 Nm (18 lbf.ft).
33.Align marks on drive plate to torque converter.
34.Fit bolts securing drive plate to torque converter
and tighten bolts to 45 Nm (33 lbf.ft).
35.Clean torque converter access plate.
36.Position access plate, fit bolts and tighten to 9
Nm (7 lbf.ft).
37.Clean end of drive shaft and mating splines in
gearbox.
38.Fit new circlip to LH drive shaft.
39.With assistance pull hub outwards, align drive
shaft and fit to gearbox, taking care not to
damage drive shaft oil seal.
CAUTION: Pull the drive shaft to ensure the
circlip is fully engaged and retains the shaft.
40.Fit splash shield and secure with bolts.
41.Position trunnion to selector lever, locate inner
cable through trunnion, do not tighten nut at this
stage.
42.Position selector cable to gearbox bracket and
secure with clip.
43.Adjust selector cable.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Selector cable - adjust.
44.Fit IRD.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.
45.Connect battery earth lead.
46.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
47.Untie and close bonnet.
Gearbox - Td4
$% 44.20.02.99
Remove
1.Disconnect battery earth lead.
2.Tie bonnet back in upright position.
3.Remove intake ducting assembly.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Ducting - intake assembly.
4.Remove fluid cooler.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Fluid cooler - Td4.
5.Remove starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - Td4.
6.Remove IRD.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - Td4.
7.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release inboard joint
from gearbox.
8.With assistance, pull hub outwards and remove
LH drive shaft from gearbox.
CAUTION: Pull the drive shaft horizontally
to avoid damaging the differential oil seal.

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-27
21.Fit new circlip to LH drive shaft.
22.With assistance, fit LH drive shaft to gearbox,
keep shaft square to prevent damage to oil seal
in gearbox.
23.Fit IRD.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - Td4.
24.Fit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - Td4.
25.Fit fluid cooler.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Fluid cooler - Td4.
26.Fit intake ducting assembly.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Ducting - intake assembly.
27.Connect battery earth lead.
28.Untie and close bonnet.
Fluid pan - reseal
$% 44.24.05
Remove
1.Drain gearbox fluid.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
2.Remove fluid cooler.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Fluid cooler - KV6.
3.Release multiplugs from clips attached to fluid
pan.
4.Remove 21 bolts securing fluid pan to gearbox.
5.Remove fluid pan.
Refit
1.Clean fluid pan and mating face on gearbox.
2.Apply sealant, Part No. STC 4600to contact
faces of fluid pan and gearbox.
3.Position fluid pan, fit bolts and tighten
progressively to 7 Nm (5 lbf.ft).
4.Secure multiplugs to clips.
5.Fit fluid cooler.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Fluid cooler - KV6.
6.Fill gearbox with fluid.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.

EXTERIOR FITTINGS
REPAIRS 76-2-7
Side rail - integral roof rack - 5 door
$% 76.11.30
Remove
1.Remove finishers from feet of side rail.
2.Remove 4 Torx screws securing side rail to roof
panel.
3.Remove side rail and 2 gaskets.
NOTE: Do not carry out further dismantling if
component is removed for access only.
4.Remove seal from each torque bolt.
5.Remove Torx bolts from side rail.
Refit
1.Fit Torx bolts and seals to replacement side rail.
2.Fit gaskets to side rail.
3.Position side rail and tighten Torx bolts to 22
Nm (16 lbf.ft).
4.Fit finishers to feet of side rail.
Bonnet
$% 76.16.01.99
Remove
1.Support bonnet in open position.
2.Fit protection covers to wings and mark hinge
outline on bonnet if bonnet is to be refitted.
3.Disconnect windscreen washer tube at elbow
joint.
4.With assistance, remove bolts securing hinges
to bonnet and remove bonnet.
Refit
1.With assistance, position bonnet to hinges. Fit
and lightly tighten bolts.
2.Connect windscreen washer tube.
3.Close bonnet. Check that bonnet is aligned to
both front wings and that gaps are equal. If
necessary, adjust bonnet alignment and/or
gaps.
4.Finally tighten hinge bolts to 9 Nm (7 lbf.ft).

EXTERIOR FITTINGS
76-2-8 REPAIRS
Cable/rod - bonnet lock control
$% 76.16.29
Remove
1.Remove bonnet lock.
2.Tie a draw string to end of bonnet release cable
and pull cable from bonnet locking platform.
3.Untie draw string from bonnet release cable.
4.Remove 3 cable ties and release bonnet
release cable from harness.5.Remove bolt securing bonnet release lever to
'A' post lower panel.
6.Remove bonnet release cable from lever and
remove lever.
7.Pull sound insulation away from bulkhead for
access to bonnet release cable grommet.
8.Remove grommet from engine bulkhead.
9.Remove bonnet release cable.

EXTERIOR FITTINGS
REPAIRS 76-2-9
Refit
1.Fit bonnet release cable through bulkhead.
2.Position bonnet release lever and connect
bonnet release cable to lever.
3.Fit release lever to 'A' post and tighten bolt to 9
Nm (7 lbf.ft).
4.Fit bonnet release cable grommet to bulkhead.
5.Position bonnet release cable to main harness
and secure with cable ties.
6.Fit sound insulation to bulkhead.
7.Tie draw string to end of bonnet release cable.
8.Pull draw string to fit bonnet release cable
through bonnet locking platform.
9.Untie draw string from bonnet release cable.
10.Fit bonnet lock.
11.Close bonnet and check for correct locking
operation.

EXTERIOR FITTINGS
76-2-10 REPAIRS
Bumper - assembly - front - up to 04MY
$% 76.22.72
Remove
1.Open bonnet.
2.Remove 8 screws securing wheel arch liners to
bumper, release liners from wheelarch for
access.
3.Remove 2 screws securing bumper valance to
underbelly panel brackets.
4.Remove 3 scrivets securing bumper to
armature.
5.Remove 2 bolts securing rear edge of front
bumper to inner front wing.
6.Remove 4 screws securing bumper to bonnet
locking platform.
7. NAS Models: Release side repeater,
disconnect multiplug and remove repeater.
8.With assistance carefully lift and pull forward
each side of bumper to release bumper side
mounts and clips.
CAUTION: Always protect paintwork when
removing or refitting any body trims or
bumpers.
9.Remove front number plate.
10.Remove badge from grill and discard clips.Refit
1.Fit badge to grill.
2.Fit number plate.
3.With assistance, fit bumper assembly to body.
4. NAS Models: Feed side repeater harness
through bumper, connect multiplug and fit
repeater.
5.Ensure bumper locating pegs are correctly
aligned.
6.Fit and tighten bolts securing bumper to wings.
7.Fit screws securing bumper to bonnet locking
platform.
8.Fit scrivets to armature.
9.Fit screws securing bumper to underbelly
panel.
10.Fit and align wheelarch liners and tighten
screws.
11.Close bonnet.

EXTERIOR FITTINGS
REPAIRS 76-2-11
Bumper - assembly - front - from 04MY
$% 76.22.72
Remove
1.Open bonnet.
2.Remove 8 screws securing wheel arch liners to
bumper, release liners from wheel arch for
access.
3.Remove 4 screws securing bumper valance to
underbelly panel.
4.Remove 3 scrivets securing bumper to
armature.5.Disconnect multiplugs from fog/driving lamps.
6.Remove 2 bolts securing rear edge of front
bumper to inner front wing.
7.Remove 4 screws securing bumper to bonnet
locking platform.
M76 4674

EXTERIOR FITTINGS
76-2-12 REPAIRS
8.With assistance, carefully pull each side of
bumper forward to release it from its
mountings.
CAUTION: Always protect paintwork when
removing or refitting any body trims or
bumpers.
9.Remove front bumper.
NOTE: Do not carry out further dismantling if
component is removed for access only.
10.Remove front number plate.
11.Remove clips securing badge to grille, remove
badge and discard clips.12.Release and remove fog/driving lamp finisher
from bumper.
13.Remove 6 screws securing fog/driving lamps to
bumper.
14.Remove 6 speed nuts from bumper.
Refit
1.Fit 6 speed nuts to bumper.
2.Fit fog/driving lamps to bumper and secure with
screws.
3.Fit fog/driving lamp finishers to bumper.
4.Fit badge to grille.
5.Fit number plate.
6.With assistance, fit bumper assembly to body.
7.Ensure bumper locating pegs are correctly
aligned.
8.Fit and tighten bolts securing bumper to wings.
9.Connect multiplugs to fog/driving lamps.
10.Fit screws securing bumper to bonnet locking
platform.
11.Fit scrivets to armature.
12.Fit screws securing bumper to underbelly
panel.
13.Fit and align wheel arch liners and tighten
screws.
14.Close bonnet.
M76 4677
M76 4679

SCREENS
REPAIRS 76-4-1
SCREENS REPAIRS
Windscreen
$% 76.81.01
The following equipment is required: Cutting wire
and handles, Windscreen repair kit, Sealer applicator
gun and Suction cups
Wear protective gloves when handling glass,
solvents and primers.
Wear suitable eye protection when removing and
refitting glass.
Remove
1.Remove air intake panel.

+ HEATING AND VENTILATION,
REPAIRS, Plenum - air intake.
2.Remove sun visors and sun visor retaining
clips.
3.Remove 'A' post upper trim casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim finisher - 'A' post - upper -
renew.
4.Remove retaining stud from front of headlining.
5.Remove interior mirror.
6.Fit protection to bonnet and areas around
screen.
7.Cover heater ducts with masking tape.
8.Cover interior of vehicle with protective sheet.
9.Make knife cut in sealant at bottom of 'A' post.
10.Insert cutting wire through previously made
knife cut and fit handles as shown, with
approximately 200 mm of wire between
handles.
11.Using suitable cutting wire, with assistance if
required, carefully cut sealer. Ensure that glass
is retained as last sealant is cut.
If multi-strand cutting wire is used, a sawing
action can be used to cut through heavy
sealant deposits around corners.
Use of a sawing action may overheat and
break single strand wire.
12.Attach suction cups and use assistance to
remove glass from body.
Lay glass on felt covered supports. Do not
stand on edge. Any chipping of glass edge
may develop into cracks.
13.Collect screen support blocks.