suspension LAND ROVER FREELANDER 2001 Owner's Manual

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.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-3
REPAIRS
Intermediate reduction drive (IRD) unit -
Td4
$% 41.25.01.99
Remove
1.Disconnect battery earth lead.
2.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.
3.Remove rear beam.

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

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - front.
5.Drain fluid from IRD.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
6.Drain gearbox fluid.

+ MANUAL GEARBOX - GETRAG,
ADJUSTMENTS, Gearbox oil - drain and
refill.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
7.Remove 3 bolts securing RH splash shield to
body and remove shield.8.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release drive shaft from
IRD.
9.With assistance, pull hub outwards and release
drive shaft from IRD.
10.Remove and discard drive shaft circlip.
11.Reference mark front propeller shaft for
reassembly.
12.Raise one rear wheel for rotation of propeller
shaft to access bolts.

INTERMEDIATE REDUCTION DRIVE
41-6 REPAIRS
Refit
1.Clean mating faces of IRD and gearbox.
2.Lubricate and fit new 'O' ring
3.With assistance, fit IRD.
4.Fit bolts securing IRD to gearbox and tighten
sufficiently only to pull mating faces of IRD and
gearbox together at this stage.
5.Fit IRD support brackets, tighten sufficiently to
pull mating faces together.
6.Final tighten bolts securing IRD to gearbox to
90 Nm (66 lbf.ft).
7.Final tighten bolts securing IRD support
brackets in the following sequence:
lM8 bolts securing support brackets to IRD
37 Nm (22 lbf.ft)
lM10 bolts securing support brackets to IRD
50 Nm (22 lbf.ft)
l3 bolts securing support bracket to cylinder
block 25 Nm (18 lbf.ft)
l3 bolts securing support bracket to sump at
45 Nm (33 lbf.ft).
8.Position lower engine steady, 'TOP' mark
uppermost. Fit bolt but do not tighten at this
stage.
9.Connect coolant hoses and secure with clips.
10.Connect breather hose to IRD housing.
11.Clean propeller shaft flange and mating face.
12.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 40 Nm (30
lbf.ft).
13.Inspect drive shaft oil seal, renew if worn or
damaged.14.Clean drive shaft and flange splines.
15.Fit new circlip to drive shaft.
16.With assistance, pull hub outwards, align drive
shaft and fit to IRD taking care not to damage
oil seal.
17.Fit splash shield and secure with bolts.
18.Fit exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - front.
19.Fit rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
20.Final tighten bolt securing lower engine steady
to IRD support bracket to 100 Nm (74 lbf.ft).
21.Remove stand(s) and lower vehicle.
22.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
23.Fill gearbox with fluid.

+ MANUAL GEARBOX - GETRAG,
ADJUSTMENTS, Gearbox oil - drain and
refill.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
24.Connect battery earth lead.
25.Refill cooling system.

+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-7
Intermediate reduction drive (IRD) unit -
K1.8
$% 41.25.01.99
Remove
1.Disconnect battery earth lead.
2.Remove rear beam.

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

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES 1.8, REPAIRS, Exhaust pipe -
front.
4.Drain fluid from IRD.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
5.Drain gearbox oil.

+ MANUAL GEARBOX - PG1,
ADJUSTMENTS, Gearbox oil - drain and
refill.
6.Remove 3 bolts securing RH splash shield to
body and remove shield.7.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release drive shaft from
IRD.
8.With assistance, pull hub outwards and release
drive shaft from IRD.
CAUTION: Care must be taken not to
damage oil seal when removing drive shaft
from IRD.
9.Remove and discard drive shaft circlip.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-9
24.Remove 3 bolts securing IRD support bracket
to sump and remove bracket.
25.Remove 4 bolts securing IRD.
26.With assistance, release IRD from gearbox and
remove.
27.Remove and discard 'O' ring from IRD.
Refit
1.Clean mating faces of IRD and gearbox.
2.Lubricate and fit new 'O' ring
3.With assistance, fit IRD.
4.Fit bolts securing IRD to gearbox and tighten
sufficiently only to pull mating faces of IRD and
gearbox together at this stage.
5.Fit IRD support bracket and tighten bolts
sufficiently only to pull mating faces together.
6.Final tighten bolts securing IRD to gearbox to
90 Nm (66 lbf.ft).
7.Final tighten bolts securing IRD support bracket
in following sequence:
l5 bolts securing IRD support bracket to IRD
50 Nm (37 lbf.ft)
l1 bolt securing support bracket to cylinder
block to 45 Nm (33 lbf.ft)
l3 bolts securing support bracket to sump 88
Nm (65 lbf.ft).8.Position engine lower steady bracket to sump,
fit and tighten bolts to 100 Nm (74 lbf.ft).
9.Fit engine lower steady, fit bolt securing steady
to gearbox bracket but do not tighten at this
stage.
10.Connect coolant hoses and secure with clips.
11.Connect breather hose to IRD housing.
12.Fit mass damper to pinion housing, fit nuts and
tighten to 25 Nm (18 lbf.ft).
13.Clean propeller shaft flange and mating face.
14.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 40 Nm (30
lbf.ft).
15.Inspect drive shaft oil seal, renew if worn or
damaged.
16.Clean drive shaft and flange splines.
17.Fit new circlip to drive shaft.
18.With assistance, pull hub outwards, align drive
shaft and fit to IRD taking care not to damage
oil seal.
CAUTION: Pull the drive shaft to ensure the
circlip is fully engaged and retains the shaft.
19.Fit splash shield and secure with bolts.
20.Fit exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES 1.8, REPAIRS, Exhaust pipe -
front.
21.Fit rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
22.Final tighten bolt securing lower engine steady
to sump bracket to 80 Nm (59 lbf.ft).
23.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
24.Refill gearbox with oil.

+ MANUAL GEARBOX - PG1,
ADJUSTMENTS, Gearbox oil - drain and
refill.
25.Connect battery earth lead.
26.Refill cooling system.

+ COOLING SYSTEM - K SERIES 1.8,
ADJUSTMENTS, Coolant - refill system.
M12 7167
M41 7698

INTERMEDIATE REDUCTION DRIVE
41-10 REPAIRS
Intermediate reduction drive (IRD) unit -
KV6
$% 41.25.01.99
Remove
1.Disconnect battery earth lead.
2.Remove rear beam.

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

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - Non
NAS.
4. NAS models: Remove RH catalytic converter.

+ EMISSION CONTROL, REPAIRS,
Catalytic converter - RH - KV6 - NAS.
5. NAS models:Remove LH exhaust manifold
gasket.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket(s) -
exhaust manifold - LH - NAS.
6.Drain fluid from IRD.

+ 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.
7.Drain gearbox fluid.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
8.Remove 3 bolts securing RH splash shield to
body and remove shield.9.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release drive shaft from
IRD.
10.With assistance, pull hub outwards and release
drive shaft from IRD.
CAUTION: Care must be taken not to
damage oil seal when removing drive shaft
from IRD.
11.Remove and discard drive shaft circlip.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-13
Refit
1.Clean mating faces of IRD and gearbox.
2.Lubricate and fit new 'O' ring
3.With assistance, fit IRD.
4.Fit bolts securing IRD to gearbox and tighten
sufficiently only to pull mating faces of IRD and
gearbox together at this stage.
5.Fit IRD support bracket and tighten bolts
sufficiently only to pull mating faces together.
6.Final tighten bolts securing IRD to gearbox to
90 Nm (66 lbf.ft).
7.Final tighten bolts securing IRD support
bracket in following sequence:
l5 bolts securing support bracket to IRD 50
Nm (37 lbf.ft)
l2 bolts securing support bracket to engine
front mounting bracket 50 Nm (37 lbf.ft)
l3 bolts securing support bracket to sump 88
Nm (65 lbf.ft).
8.Position lower engine steady, 'TOP' mark
uppermost. Fit bolt but do not tighten at this
stage.
9.Connect coolant hoses and secure with clips.
10.Connect breather hose to IRD housing.
11.Fit manifold heat shield and fit nut securing
heat shield to pinion housing finger tight.
12.Fit bolts securing manifold heat shield to IRD
support bracket and tighten to 9 Nm (7 lbf.ft).
13.Fit nut securing heat shield to IRD and tighten
to 45 Nm (33 lbf.ft).
14.Final tighten nut securing manifold heat shield
to IRD pinion housing to 25 Nm (18 lbf.ft).
15.Clean propeller shaft flange and mating face.
16.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 40 Nm (30
lbf.ft).
17.Inspect drive shaft oil seal, renew if worn or
damaged.
18.Clean drive shaft and flange splines.
19.Fit new circlip to drive shaft.
20.With assistance, pull hub outwards, align drive
shaft and fit to IRD taking care not to damage
oil seal.
CAUTION: Pull the drive shaft to ensure the
circlip is fully engaged and retains the shaft.21.Fit splash shield and secure with bolts.
22.Fit exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - Non
NAS.
23.Fit rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
24.Final tighten bolt securing lower engine steady
to IRD support bracket to 100 Nm (74 lbf.ft).
25.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.
26. NAS models: Fit RH catalytic converter.

+ EMISSION CONTROL, REPAIRS,
Catalytic converter - RH - KV6 - NAS.
27. NAS models: Fit LH exhaust manifold gasket.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket(s) -
exhaust manifold - LH - NAS.
28.Fill gearbox with fluid.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
29.Connect battery earth lead.
30.Refill cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.

DRIVESHAFTS
REPAIRS 47-7
10.With assistance pull hub assembly outwards
and release drive shaft outer joint from hub
assembly.
11.Taking care not to damage 'Flinger', release
drive shaft inner joint from differential using
LRT-51-014 and remove drive shaft.
12.Remove and discard drive shaft circlip.Refit
1.Inspect differential seal, renew if worn or
damaged.
2.Clean ends of drive shaft and locations in hub
and differential.
3.Lubricate oil seal running surface with
transmission oil.
4.Fit new circlip to drive shaft.
5.Fit drive shaft to differential and push fully
home.
CAUTION: Pull the drive shaft to ensure the
circlip is fully engaged and retains the shaft.
6.With assistance fit drive shaft to hub.
7.Fit new drive shaft nut but do not tighten at this
stage.
8.Fit nut, bolt and dynamic damper to adjustable
transverse link and tighten to 120 Nm (89 lbf.ft).
CAUTION: Nuts and bolts must be tightened
with the weight of the vehicle on the
suspension.
9.Fit nut and bolt to fixed transverse link and
tighten to 120 Nm (89 lbf.ft).
10.Fit spacer, nut and bolt to trailing link and
tighten to 120 Nm (89 lbf.ft).
11.Fit new drive shaft nut and tighten to 400 Nm
(295 lbf.ft). Stake nut to shaft.
12.Check and top up oil level.

+ MAINTENANCE, MAINTENANCE,
Rear Axle.
13.Fit road wheel(s) and tighten nuts to 115 Nm 85
lbf.ft).
14.Remove stands and lower vehicle.
15.Connect battery earth lead.

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.