radiator LAND ROVER FREELANDER 2001 Owner's Manual

PANEL REPAIRS
REPAIRS 77-2-31
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit insulation pads to engine bulkhead.
2.Position front carpet and fit treadplate to front
door aperture. 3. Driver's side: Fit clutch pedal box.
4. Driver's side: Fit brake pedal box and brake
servo.
5. Driver's side: Fit passenger compartment fuse
box.
6. LH side: Fit horn.

+ SECURITY, REPAIRS, Horn.
7. LH side: Fit air intake hose.
8. LH side: Fit battery. Do not connect battery
earth lead.

+ CHARGING AND STARTING,
REPAIRS, Battery.
9. LH side: Fit LH engine mounting to body.
10. LH side: Fit front bumper LH support bracket.
11. RH side: Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
12. RH side: Fit RH engine mounting to body.
13. RH side: Fit front bumper RH support bracket.
14.Fit fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
15.Fit PAS rack.

+ STEERING, REPAIRS, Power
steering rack.
16.Fit engine and gearbox.

+ ENGINE - K SERIES KV6, REPAIRS,
Engine and automatic gearbox - up to 03MY.
17.Fit front suspension rear beam.
18.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
19.Fit engine bay shield.
20.Fit headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
21.Secure headlamp wiring.
22.Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
23.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
24.Fit front bumper armature.
25.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
26.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
27.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
28.Connect all ECUs.
29.Connect alternator.
30.Connect battery earth lead.

PANEL REPAIRS
77-2-32 REPAIRS
Front sidemember (front section)
In this procedure, the front section of the front
sidemember closing panel and the related
crossmember to sidemember gusset plate are
replaced in conjunction with the front sidemember.
Remove
1.Disconnect battery earth lead.
2.Disconnect all ECUs.
3.Remove road wheel(s).
4.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
6.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
7.Remove PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
8.Remove headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
9.Release wiring to headlamp and position aside.
10.Remove engine bay shield.
11.Remove front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
12. LH side: Remove front bumper LH support
bracket.
13. LH side: Remove ECM.
14. LH side: Remove battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
15. LH side: Remove air cleaner.
16. LH side: Remove air intake hose.
17. LH side: Remove horn.

+ SECURITY, REPAIRS, Horn.
18. RH side: Remove front bumper RH support
bracket.
19. RH side: Remove windscreen washer
reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
20. RH side: Remove alternator.

+ CHARGING AND STARTING,
REPAIRS, Alternator - KV6.
21. RH side: Remove PAS pump.

+ STEERING, REPAIRS, Pump -
steering - KV6.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.

PANEL REPAIRS
REPAIRS 77-2-33
Refit
1. LH side: Fit horn.

+ SECURITY, REPAIRS, Horn.
2. LH side: Fit air intake hose.
3. LH side: Fit air cleaner.
4. LH side: Fit battery carrier. Do not connect
battery earth lead.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
5. LH side: Fit ECM.
6. LH side: Fit front bumper LH support bracket.
7. RH side: Fit PAS pump.

+ STEERING, REPAIRS, Pump -
steering - KV6.
8. RH side: Fit alternator.

+ CHARGING AND STARTING,
REPAIRS, Alternator - KV6.
9. RH side: Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
10. RH side: Fit front bumper RH support bracket.
11.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
12.Fit engine bay shield.
13.Fit headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
14. Secure headlamp wiring.
15.Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
16.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
17.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
18.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
19.Connect all ECUs.
20.Connect battery earth lead.
Front valance assembly
Remove
1.Disconnect battery earth lead.
2.Disconnect all ECUs.
3.Remove road wheel(s).
4.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
6.Remove front bumper armature.
7.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
8.Remove PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
9.Remove headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
10.Release wiring to headlamp and position aside.
11.Remove engine bay shield.
12.Remove front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
13.Remove front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
14.Remove front suspension rear beam.
15.Remove engine and gearbox.

+ ENGINE - K SERIES KV6, REPAIRS,
Engine and automatic gearbox - up to 03MY.
16.Remove front damper.

+ FRONT SUSPENSION, REPAIRS,
Damper.
17.Remove PAS rack.

+ STEERING, REPAIRS, Power
steering rack.
18.Remove fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
19. LH side: Remove front bumper LH support
bracket.
20. LH side: Remove air cleaner.
21. LH side: Remove air intake hose.
22. LH side: Remove ECM.
23. LH side: Remove engine compartment
fusebox.
24. LH side: Remove battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
25. LH side: Remove engine compartment fuse
box and related wiring.

PANEL REPAIRS
REPAIRS 77-2-35
29.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
30.Fit engine bay shield.
31.Fit headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
32.Secure headlamp wiring. Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
33.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
34.Fit front bumper armature.
35.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
36.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
37.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
38.Connect all ECUs.
39.Connect battery earth lead.

PANEL REPAIRS
REPAIRS 77-2-37
Valance front
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
6.Remove engine bay shield.
7.Remove front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
8.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
9.Remove front bumper support bracket.
10.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
11.Remove headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
12.Release wiring to headlamp and position aside.
13. LH side: Remove air cleaner.
14. LH side: Remove air intake hose.
15. LH side: Remove ECM.
16. LH side: Remove battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
17. LH side: Remove engine compartment fuse
box and related wiring.
18. LH side: Remove LH front brake pipe.
19. RH side: Remove PAS fluid reservoir.
20. RH side: Remove RH front brake pipe.
21. RH side: Remove windscreen washer
reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
22. RH side: Remove PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.

PANEL REPAIRS
77-2-38 REPAIRS
Refit
1. LH side: Fit LH front brake pipe. Bleed brake
system.

+ BRAKES, ADJUSTMENTS, Brake
bleed.
2. LH side: Fit engine compartment fuse box and
related wiring.
3. LH side: Fit battery carrier. Do not connect
battery earth lead.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
4. LH side: Fit ECM.
5. LH side: Fit air intake hose.
6. LH side: Fit air cleaner.
7. RH side: Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
8. RH side: Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
9. RH side: Fit RH front brake pipe. Bleed brake
system.

+ BRAKES, ADJUSTMENTS, Brake
bleed.
10. RH side: Fit PAS fluid reservoir.
11.Fit headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
12.Secure headlamp wiring.
13.Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
14.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
15.Fit front bumper support bracket.
16.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
17.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
18.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
19.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
20.Connect all ECUs.
21.Connect alternator.
22.Connect battery earth lead.

AIR CONDITIONING
82-10REPAIRS
Condenser
$% 82.15.07
Remove
1.Disconnect battery earth lead.
2.Recover refrigerant from A/C system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery -
recycling and recharge.
3. Td4 models: Remove intercooler.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Intercooler.
4. Remove bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5. KV6 models: Remove 2 bolts securing PAS
fluid cooler to armature.
6. Up to 04MY: Remove 4 nuts and 4 bolts
securing armature to body, remove armature.
7. 04MY on: Remove 4 bolts securing armature to
crash cans and remove armature.8.If fitted, remove 4 scrivets securing LH and RH
air deflectors, remove both deflectors.
9.Remove 2 bolts securing condenser to radiator.
10.Remove 2 bolts securing receiver drier
mounting brackets to radiator.

M76 4176

AIR CONDITIONING
REPAIRS 82-11
11.Remove 2 bolts securing A/C pipes to
condenser and release pipes from condenser.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
12.Remove and discard 'O' rings from A/C pipes.
13.Remove condenser.
14.Remove 8 screws, securing 4 mounting
brackets to condenser and move aside.
15.Remove and discard receiver drier, plug
connections.Refit
1.Fit condenser mounting brackets, fully tighten
LH screws. Leave RH screws loose until
receiver drier is fitted.
CAUTION: Ensure that bolts of the correct
length are used on refit.
2.Lubricate new 'O' rings with clean refrigerant
oil, fit one seal to each condenser pipe.
3.Position A/C pipes to condenser, fit bolts and
tighten to 8 Nm (6 lbf.ft).
4.Fit bolts securing condenser to radiator and
tighten to 8 Nm (6 lbf.ft).
5.Fit receiver drier assembly to condenser.

+ AIR CONDITIONING, REPAIRS,
Receiver drier.
6.Fit air deflectors and secure with scrivets.
7. Up to 04MY: Position armature, fit and tighten
4 nuts and bolts securing armature to body to
25 Nm (18 lbf.ft).
8. 04MY on: Position armature, fit bolts securing
armature to crash cans and tighten to 25 Nm
(18 lbf.ft).
9. KV6 models:Align PAS fluid cooler and tighten
bolts to 8 Nm (6 lbf.ft).
10.Fit bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
11. Td4 models: Fit intercooler.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Intercooler.
12.Recharge A/C system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery -
recycling and recharge.
13.Connect battery earth lead.
M82 0706