brake fluid LAND ROVER FREELANDER 2001 Owner's Manual

ENGINE - K SERIES KV6
REPAIRS 12-3-33
71.Remove 3 bolts securing PAS pump to front
mounting plate and tie pump aside.
72.With assistance, manoeuvre and lower engine
and gearbox to floor.
Refit
1.With assistance, raise engine and gearbox into
engine compartment.
2.Position PAS pump to front mounting plate, fit
and tighten bolts to 25 Nm (18 lbf.ft).
3.Position PAS pump pulley, fit and tighten Torx
screws to 9 Nm (7 lbf.ft).
4.Position top arm to engine mounting bracket
and RH hydramount, fit and tighten bolts to 100
Nm (74 lbf.ft).
5.Position PAS pipe support bracket to RH
hydramount, fit and tighten nut to 85 Nm (63
lbf.ft).
6.Place a wooden block on jack, position jack
under gearbox and raise jack sufficient to
support weight of gearbox. Release lifting hook
from lifting bracket on gearbox and connect to
rear engine lifting bracket.
7.Lower and remove jack supporting gearbox.
8.Remove bolts securing LRT-44-026 lifting
bracket to gearbox and remove bracket.
9.Position LH mounting bracket to gearbox, fit
and tighten bolts to 85 Nm (63 lbf.ft).
10.Position LH mounting to body, fit and tighten
bolts to 48 Nm.
11.Align gearbox bracket to LH body mounting, fit
and tighten through bolt to 100 Nm (74 lbf.ft).
12.Position upper RH engine steady to top arm, fit
and tighten bolt to 100 Nm (74 lbf.ft).
13.Tighten bolt securing upper RH engine steady
to body to 100 Nm (74 lbf.ft).
14.Position PAS pipe to engine front mounting
plate, fit and tighten bolt to 25 Nm (18 lbf.ft).
15.Lower hoist, disconnect and remove lifting
bracket, LRT-12-138.
16.Raise vehicle on ramp.17.Position A/C compressor to front mounting
plate and cylinder block, align heat shield, fit
and tighten bolts to 25 Nm (18 lbf.ft).
18.Connect multiplug to A/C compressor.
19.Using a 3/8 square drive socket bar, raise
ancillary drive belt tensioner and fit drive belt to
pulleys.
20.Position selector cable to gearbox bracket and
secure with clip.
21.Position selector lever to selector shaft, fit and
tighten nut to 25 Nm (18 lbf.ft).
22.Clean splines and seal areas on each
driveshaft and mating faces in front hubs.
23.Fit new circlips to RH and LH driveshaft inner
joint splines.
24.Fit driveshafts to IRD and gearbox, ensuring
that the circlip on each driveshaft is fully
engaged.
25.Engage LH and RH driveshafts into front hubs.
26.Fit new driveshaft flange nuts but do not tighten
at this stage.
27.Clean ball joint tapers and taper seats.
28.Position LH and RH track rod ends to steering
arms, fit new nuts and tighten to 55 Nm (40
lbf.ft).
29.Clean ABS sensors and mating faces.
30.Apply anti-seize grease to both ABS sensors
and position sensors in front hubs.
Ensure ABS sensor is fully located into hub,
so that sensor touches pole wheel teeth.
31.Position LH and RH brake hoses to front
damper brackets and secure with clips.
32.Position LH and RH splash shields, fit and
tighten bolts.
33.Ensure mating face of propeller shaft and IRD
drive flange are clean.
34.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 42 Nm (31
lbf.ft).
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) fluid - drain & refill -
Non NAS.

+ 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 - Non
NAS.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - NAS.

ENGINE - K SERIES KV6
12-3-34 REPAIRS
38.With assistant depressing the brake pedal,
tighten front hub nuts to 400 Nm (295 lbf.ft).
39.Stake nut to shaft.
40.Fit front road wheels, fit and tighten nuts to 115
Nm (85 lbf.ft).
41.Lower vehicle on ramp.
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, if fitted.
48.Secure throttle cable in clips on harness
brackets, if fitted.
49.Adjust throttle cable, if fitted.

+ FUEL DELIVERY SYSTEM -
PETROL, ADJUSTMENTS, Throttle cable -
check and adjust - KV6.
50.Connect hose to purge control valve.
51.Connect fuel hose to fuel rail pipe, fit rubber
sleeve over hose connector.
52.Connect gearbox harness multiplugs and
secure multiplugs in mounting bracket clips.
53.Connect Lucar connector to starter solenoid.
54.Position earth lead to gearbox housing, fit and
tighten bolt to 25 Nm (18 lbf.ft).
55.Position engine harness to 'E' box mounting
bracket and secure with clips.
56.Connect earth header multiplug.
57.Connect multiplug to underbonnet fuse box.
58.Position battery and starter motor lead to
underbonnet fuse box, fit and tighten bolts to 8
Nm (6 lbf.ft).
59.Fit underbonnet fuse box cover.
60.Position 'E' box, secure in retaining clip, fit and
tighten nut to 9 Nm (7 lbf.ft).
61.Position carrier in 'E' box and secure with clips.
62.Position and secure air duct and harness
rubber sleeve in 'E' box.
63.Connect multiplugs securing main harness to
engine harness.
64.Position ECM harness and multiplug to 'E' box,
align harness clamp and secure screws to 'E'
box.
65.Fit engine ECM.

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

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.67.Fill cooling system.

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

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

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

ENGINE - K SERIES KV6
REPAIRS 12-3-39
37.Raise vehicle on lift.
38.Remove front road wheels.
39.Release stake in drive shaft nuts.
40.With assistant depressing the brake pedal,
remove and discard LH and RH drive shaft
nuts.
41.Remove rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
42.Remove exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - NAS.
43.Raise one rear wheel for rotation of propeller
shaft to access bolts.
44.Reference mark position of viscous coupling
flange to IRD unit flange to aid reassembly.
45.Remove 6 nuts and bolts securing propeller
shaft to IRD drive flange.
46.Release propeller shaft from IRD drive flange
and tie shaft aside.
CAUTION: Care must be taken to support
the Tripode joint when removed from the
IRD unit. To avoid damage to gaiter or steel
can, the joint should not be allowed to fully
extend or be dropped.47.Drain gearbox fluid.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
48.Drain fluid from IRD.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
49.Remove 6 bolts securing RH and LH front
splash shields and remove shields.
50.Remove clips securing brake hoses to RH and
LH damper brackets.
51.Release ABS sensor leads from bracket.
52.Release ABS sensors from RH and LH front
hubs.
M12 6614

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.

AUTOMATIC GEARBOX - JATCO
44-2 ADJUSTMENTS
Gearbox fluid - drain & refill
$% 44.24.02
Drain
1.Position vehicle on ramp.
WARNING: Observe due care when draining
gearbox fluid as the fluid can be very hot.
2.Apply handbrake and position chocks under
front and rear wheels.
3.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
4.Position container under gearbox.
NOTE: The fluid should be drained with the
transmission at normal operating temperature.
5.Clean area around drain plug.
6.Remove drain plug and discard sealing washer.
7.Allow fluid to drain.
8.Clean drain plug and fit new sealing washer.
9.Fit drain plug and tighten to 45 Nm (33 lbf.ft).Refill
1.Clean area around filler plug.
2.Remove filler plug.
3.Add 3.5 to 4 litres of the correct fluid through
gearbox filler.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
4.Clean and fit filler plug.
5.Check and top-up fluid level.

+ MAINTENANCE, MAINTENANCE,
Automatic Gearbox – JATCO.
6.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
M44 1641
M44 1642

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.

REAR SUSPENSION
REPAIRS 64-5
7.Fit hub to damper and tighten bolts to 205 Nm
(151 lbf.ft).
CAUTION: Nuts and bolts must be tightened
with weight of vehicle on suspension.
8.Fit nut, bolt and washers securing transverse
links to hub and tighten nut to 105 Nm (77 lbf.ft).
9.Fit trailing link to hub and tighten nut and bolt to
120 Nm (89 lbf.ft).
NOTE: Ensure that washers are fitted to both
ends of bolts
10.Clean ABS sensor, smear sensor with an anti-
seize grease and fit sensor to hub.
CAUTION: Ensure ABS sensor is fully
located into hub, so that sensor touches
pole wheel teeth.
11.Fit brake pipe to wheel cylinder and tighten
union to 14 Nm (10 lbf.ft).
12.Fit clip securing brakepipe to bracket.
13.Fit and secure handbrake cable to backplate.
14.Fit brake shoes.

+ BRAKES, REPAIRS, Brake Shoes -
rear set.
15.Fit new drive shaft nut and tighten to 400 Nm
(295 lbf.ft). Stake nut to shaft.
16.Bleed brakes.

+ BRAKES, ADJUSTMENTS, Brake
bleed.
17.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
18.Remove stands and lower vehicle.
Damper
$% 64.30.02
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.Clamp brake hose to prevent fluid loss.
4.Position absorbent cloth to catch spillage.
5.Loosen brake pipe union to hose and release
union.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Remove clip securing brake hose to bracket on
damper. Release brake hose from bracket.
7.Release ABS sensor harness and brake hose
from damper.
8.Release ABS sensor from hub.

BRAKES
ADJUSTMENTS 70-1
BRAKES ADJUST ME NTS
Brake bleed
$% 70.25.02
Check
1.The following procedure covers bleeding the
complete system but where only the primary or
secondary circuit have been disturbed in
isolation, it should only be necessary to bleed
that system. Partial bleeding of the hydraulic
system is only permissible if a brake pipe or
hose has been disconnected with only minor
loss of fluid.
CAUTION: Ensure the fluid in the reservoir
is maintained between the minimum and
maximum levels throughout the bleed
procedure using new brake fluid.
Adjust
1.Raise front and 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.Check all pipe and hose connections are tight
and there are no signs of leakage.
3.Top-up fluid level in brake reservoir to 'MAX'
mark.

+ MAINTENANCE, MAINTENANCE,
Brake Fluid.
CAUTION: Never re-use fluid that has been
bled from the system.
4.Bleed sequence: LH front to RH front, LH rear
to RH rear.
CAUTION: Use only new brake fluid of the
recommended grade.5.Attach bleed tube to front brake caliper bleed
screw on passenger side, submerge free end in
a clear container containing brake fluid.
CAUTION: Brake fluid will damage paint
finished surfaces. If spilled, immediately
remove fluid and clean area with water.
6.Apply pressure to brake pedal several times,
then apply steady pressure.
7.Loosen bleed screw to release brake fluid and
air. Allow pedal to return unassisted.
8.Depress brake pedal steadily through its full
stroke and allow to return unassisted. Repeat
procedure until a flow of clean air-free fluid is
purged into container then, whilst holding pedal
at end of downward stroke tighten bleed screw
to 10 Nm (7.5 lbf.ft) on calipers and 8 Nm (6
lbf.ft) on wheel cylinders.
CAUTION: Ensure the fluid in the reservoir
is maintained between the minimum and
maximum levels throughout the bleed
procedure using new brake fluid.
9.Top up brake system reservoir.
10.Repeat procedure at each wheel in the
sequence shown.
WARNING: Braking efficiency may be
seriously impaired if the incorrect bleed
sequence is used.
11.Remove tube from bleed screw and fit bleed
screw dust cap.
12.Apply brakes and check for leakage.
13.Remove stands and lower vehicle.
14.Road test vehicle. Check brake pedal for short
firm travel when brakes are applied.

BRAKES
70-4 REPAIRS
Refit
1.Renew brake drum if scored, grooved or
cracked.
2.Check wheel cylinder pistons for freedom of
movement.
3.Clean backplate and brake drum with brake
cleaning fluid.
WARNING: Do not use petroleum based
fluid as damage will occur to rubber
components
4.Measure inside diameter of drum at 2 points.
Drum internal diameter: New = 254 mm.
Service limit: = 255.49 mm. Drum ovality limit:
= 0.012 mm. Renew drum if outside limits.
5.Examine wheel cylinder dust seals for signs of
brake fluid leakage, a certain amount of
dampness is usual. However, if excessive fluid
is apparent, lift dust seals and check for
leakage. Renew wheel cylinders and brake
shoes if linings are contaminated.
6.Apply molykote 111 grease to brake shoe and
spring contact points.
WARNING: Ensure grease does not contact
brake shoe linings or wheel cylinder dust
covers.
Check adjuster ratchet and if necessary set to
minimum adjustment position as follows: Lever
leading shoe away from wheel cylinder; Move
adjuster ratchet back fully; Ease shoe back into
position.7.Fit brake drum and tighten screws.
8.If necessary, fit backplate grommet.
9.Apply brake pedal a min. of 30 times to ensure
full adjustment of rear brake shoes after
refitting.
10.Check handbrake operation, adjust if
necessary.
11.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
12.Remove stands and lower vehicle.

BRAKES
70-8 REPAIRS
Cylinder - master - tandem - LHD
$% 70.30.08
Remove
1.Disconnect brake fluid level multiplug.
2.Position cloth under master cylinder to absorb
spilled fluid.
CAUTION: Brake fluid will damage paint
finished surfaces. If spilled, immediately
remove fluid and clean area with water.
3.Disconnect secondary system pipe union from
master cylinder.
4.Disconnect primary system pipe union from
master cylinder.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove Torx bolt securing master cylinder
reservoir to access master cylinder retaining
nut.6.Remove and discard 2 nuts securing master
cylinder to servo, remove master cylinder.
7.Refit Torx bolt to reservoir.
8.Remove and discard sealing ring.
Refit
1.Clean master cylinder and servo mating
surfaces.
2.Remove Torx bolt securing brake fluid reservoir
to master cylinder.
3.Fit new sealing ring to master cylinder.
4.Align push rod and position master cylinder to
servo.
5.Fit new nuts and tighten 25 Nm (18 lbf.ft).
6.Fit Torx bolt securing reservoir to master
cylinder and tighten to 8 Nm (6 lbf.ft).
7.Clean brake pipe unions.
8.Connect primary and secondary brake pipes
and tighten unions 17 Nm (12 lbf.ft).
9.Connect fluid level switch multiplug.
10.Bleed brakes.

+ BRAKES, ADJUSTMENTS, Brake
bleed.
M70 1067