engine LAND ROVER FREELANDER 2001 Workshop Manual

BRAKES
70-2 ADJUSTMENTS
Cable - handbrake - check and adjust
$% 70.35.10
Check
1.Release ash tray panel from rear console,
disconnect multiplug from power socket and
remove ash tray panel.
2.Fully release handbrake lever.
3.With engine running, apply footbrake a
minimum of thirty times, to ensure full
adjustment of rear brake shoes.
4.Switch off engine.
5.Apply handbrake lever one notch at a time and
count the number of notches required to apply
the brakes firmly, equivalent to a pull of 20 kgf.
applied at mid point of handbrake lever grip.
Handbrake lever travel = 4 to 7 notches.
6.Adjust handbrake cable tension if travel is
outside limits.
CAUTION: Hand brake travel must be within
the limits given or the automatic adjusters
may not work.Adjust
1.If carrying out handbrake adjustment after
brake drum installation, apply brake pedal a
min. of 30 times, to ensure full adjustment of
rear brake shoes.
2.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.
3.Check handbrake cable connections for free
movement in handbrake equalizer.
4.Apply handbrake lever one notch.
5.Tighten equalizer adjusting nut until rear
wheels drag slightly when turned.
6.Release handbrake lever and check that rear
wheels do not drag when turned. Adjust if
necessary.
7.Apply handbrake one notch at a time and count
the number of notches until both rear wheels
lock. This should be a minimum of 4 and a
maximum of 7 clicks. Adjust if necessary.
8.Release handbrake
9.Fit ash tray panel and cigar lighter to rear
console.
10.Remove stands and lower vehicle.

BRAKES
REPAIRS 70-19
Servo assembly - RHD
$% 70.50.01
Remove
1. KV6 models: Remove engine acoustic cover.
2. Td4 models: Remove air cleaner element

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Element - air cleaner.
3.Remove brake master cylinder.

+ BRAKES, REPAIRS, Cylinder -
master - tandem - RHD.
4.Release and disconnect vacuum hose from
servo.
5.Remove and discard vacuum hose seal.
6.Release brake pipes from clips on bulkhead.7.Remove clip and clevis pin securing brake
servo push rod to brake pedal.
8.Remove 4 nuts securing servo to body and
remove servo.
9.Remove and discard gasket.
Refit
1.Fit new gasket to servo.
2.Position servo to body, fit nuts and tighten to 22
Nm (16 lbf.ft).
3. Align push rod to brake pedal, fit clevis pin and
secure with new spring clip.
4.Fit new vacuum hose seal.
5.Connect vacuum hose to servo.
6.Fit brake master cylinder.

+ BRAKES, REPAIRS, Cylinder -
master - tandem - RHD.
7.Secure brake pipes in retaining clips.
8. Td4 models: Fit air cleaner element.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Element - air cleaner.
9. KV6 models: Fit engine acoustic cover.

BRAKES
REPAIRS 70-21
Vacuum pump - Td4 - automatic
$% 70.50.19
Remove
1.Disconnect battery earth lead.
2.Remove camshaft cover.

+ ENGINE - Td4, REPAIRS, Gasket -
camshaft cover.
3.Mark EGR pipe and cooler to aid refit.
4.Loosen clamps EGR pipes to cooler and move
clamps aside.
5.Remove pipe, EGR cooler to EGR valve.
6.Remove bolt securing fuel rails to support
bracket.
7.Remove bolt securing intercooler pipe to
support bracket.
8.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.9.Remove bolt securing turbo outlet pipe to upper
coolant rail.
10.Remove 2 bolts securing pipe support bracket
to engine lifting bracket, remove support
bracket.
11.Release clip and remove vacuum hose.
12.Remove and discard 2 bolts securing vacuum
pump.

M17 0283

BRAKES
70-22 REPAIRS
13.Remove 3 bolts securing EGR cooler to
cylinder head and lifting bracket.
14.Move EGR cooler aside for access to vacuum
pump.
15.Remove vacuum pump and discard 'O' ring.
Refit
1.Clean vacuum pump and mating face.
2.Fit new seal to vacuum pump, fit vacuum pump
and tighten new bolts to 22 Nm (16 lbf.ft).
3.Position EGR cooler to mounting, fit bolts and
tighten to 25 Nm (18 lbf.ft).
4.Position pipe support bracket to engine lifting
bracket, fit and tighten bolts to 25 Nm (18 lbf.ft).
5.Fit vacuum hose and tighten clip.
6.Fit bolt securing turbocharger pipe to coolant
rail and tighten to 25 Nm (18 lbf.ft).
7.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
8.Fit bolt securing turbocharger intercooler pipe
to support bracket and tighten to 10 Nm (7.5
lbf.ft).
9.Fit bolt securing fuel rails to support bracket
and tighten to 10 Nm (7.5 lbf.ft).
10.Align EGR pipe to cooler, fit clamp but do not
fully tighten until camshaft cover is refitted.
11.Fit EGR pipe clamp and tighten screw.
12.Fit camshaft cover.

+ ENGINE - Td4, REPAIRS, Gasket -
camshaft cover.
13.Connect battery earth lead.
Vacuum - enhancer - KV6
$% 70.50.20
Remove
1.Disconnect battery earth lead.
2.Remove engine accoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Release enhancer from support clips.
4.Disconnect multiplug from solenoid valve if
fitted.
5.Release and disconnect servo pipe.
6.Release clip and disconnect from intake hose.
7.Release and remove enhancer assembly from
inlet manifold.
Refit
1.Fit enhancer to inlet manifold.
2.Connect to intake hose and secure with clip.
3.Connect servo hose.
4.Connect multiplug to solenoid valve if fitted.
5.Fit enhancer into clips.
6.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
7.Connect battery earth lead.

BRAKES
70-30 REPAIRS
Modulator unit
$% 70.65.49
Remove
1. Td4 and KV6 models: Remove engine
accoustic cover if fitted.

+ ENGINE - Td4, REPAIRS, Cover -
engine acoustic - Up to 02.5 Model Year.
2. Td4 and KV6 models: Release and remove air
intake hose.
3. Td4 and KV6 models: Release clip securing
harness and intake duct to body.
4. Td4 and KV6 models: Lift duct from body,
release clip from washer reservoir filler hose.
5. Td4 and KV6 models: Release and remove air
intake duct.
6. Td4 models: Loosen 2 clips and remove
intercooler outlet hose.7.Remove 2 bolts securing PAS oil cooler pipes.
8.Release PAS reservoir from mounting bracket
and position aside.
9.Release catch and disconnect ABS modulator
multiplug.
10.Position cloth under modulator to absorb fluid
spillage.
CAUTION: Brake fluid will damage paint
finished surfaces. If spilled, immediately
remove fluid and clean area with water.
11.Disconnect 2 inlet brake pipes unions from ABS
modulator.
12.Disconnect 4 outlet brake pipes unions from
ABS modulator.
CAUTION: Always fit plugs to open
connections to prevent contamination.
13.Remove 3 bolts securing ABS modulator to
mounting bracket.
14.Release and remove ABS modulator from
mounting bracket.
M70 1085
M70 1083
M70 1088

BRAKES
REPAIRS 70-31
Refit
1.Position modulator to mounting bracket fit bolts
and tighten to 9 Nm (7 lbf.ft).
2.Clean brake pipe unions.
3.Connect brake pipe unions to modulator
ensuring pipes are connected to their correct
ports.
4.Tighten unions to 17 Nm (12 lbf.ft).
5.Connect ABS modulator multiplug and secure
catch.
6. Td4 and KV6 models: Position air intake duct
to body.
7. Td4 and KV6 models: Secure intake duct to
washer bottle filler neck and harness clip.
8. Td4 and KV6 models: Fit air intake hose.
9.Fit PAS reservoir to mounting bracket.
10.Fit bolts securing PAS oil cooler pipes and
tighten to 10 Nm (7.5 lbf.ft).
11. Td4 models: Fit intercooler outlet hose and
tighten clips.
12. Td4 and KV6 models: Fit engine accoustic
cover if fitted.

+ ENGINE - Td4, REPAIRS, Cover -
engine acoustic - Up to 02.5 Model Year.
13.Bleed brakes.

+ BRAKES, ADJUSTMENTS, Brake
bleed.
14.To ensure correct operation, the ABS system
MUST be tested using TestBook/T4.
Switch - hill descent - from 04MY
$% 70.70.11
Remove
1.Working from forward edge, carefully release
spring clip securing gear selector indicator
assembly to centre console. Release 2
additional clips at the sides and slide assembly
forward.
2.Disconnect multiplug from hill descent switch.
3.Remove hill descent switch from gear selector
indicator assembly.
Refit
1.Fit and secure hill descent switch to gear
selector indicator assembly.
2.Connect hill descent control switch multiplug.
3.Fit and secure gear selector indicator assembly
to centre console.

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.

PANEL REPAIRS
BODY REPAIRS 77-2-1
PANEL REPAIRS
General
Body shells are of monocoque construction. Front and rear sections of the shell are designed as 'energy absorbing'
zones. This means they are designed to deform progressively when subjected to impact in order to minimise the
likelihood of injury to vehicle occupants.
It is essential that design dimensions and strength are restored in accident rectification. It is important that neither
structural weakness nor excessive local stiffness are introduced into the vehicle during body repair.
Repairs usually involve a combination of operations ranging from straightening procedures to renewal of individual
panels or panel assemblies. The repairer will determine the repair method and this decision will take into account a
balance of economics between labour and material costs and the availability of repair facilities in both equipment and
skills. It may also involve considerations of the vehicles' downtime, replacement vehicle availability and repair turn-
around time.
It is expected that a repairer will select the best and most economic repair method possible, making use of the facilities
available. The instructions given are intended to assist a skilled body repairer by expanding approved procedures for
panel replacement. The objective is to restore the vehicle to a safe running condition by carrying out a repair which is
as close as is feasible to original standard. The results should not advertise to the experienced eye that the vehicle
has been damaged, although the repair might not be identical in all respects to the original factory build. Commercial
bodyshop repair facilities cannot always duplicate methods of construction used during production.
Operations covered in this Manual do not include reference to testing the vehicle after repair. It is essential that work
is inspected and suspension geometry checked after completion. Where necessary a road test of the vehicle should
be carried out, particularly where safety-related items are concerned.
Where major units have been disconnected or removed it is necessary to ensure that fluid levels are checked and
topped up where necessary. It is also necessary to ensure that the repaired vehicle is in a roadworthy condition in
respect of tyre pressures, lights, washer fluid etc.
Body repairs often involve the removal of mechanical and electrical units and associated wiring. Where necessary,
refer to the relevant section of the Workshop Manual for removal and refitting instructions.
Body components
Taking into consideration the differences in body styles, suspension systems and engine and transmission layouts,
the location of the following components as applicable to a particular vehicle is critical:
lFront suspension upper damper mountings.
lFront suspension or sub frame mountings.
lRear suspension upper damper mountings.
lRear suspension mountings or lower pivots.
Additional points which can be used to check alignment and assembly are:
lInner holes in crossmember - side - main floor.
lHoles in front longitudinals.
lHoles in side members.
lHoles in rear longitudinals.
lHoles in rear lower panels or extension rear floor.
Apertures for windscreen, backlight, bonnet and doors can be measured and checked using the dimensional
information provided and also by offering up an undamaged component as a gauge.
Straightening
Whenever possible, structural members should be cold straightened under tension. Do not attempt to straighten with
a single pull but rework the damaged area using a series of pulls, releasing tension between each stage and using
the opportunity to check alignment.

PANEL REPAIRS
WELDING PROCEDURES 77-2-15
WE LDING PROCEDURE S
ECU locations (3 door model shown, 5
door model similar)
1Central control unit (on forward side of
passenger compartment fusebox, behind
driver's glove box)
2RF Receiver (on top of instrument pack)
3Immobiliser ECU (rear of fascia)
4DCU (SRS on transmission tunnel below
heater)
5EAT ECU (inside Environmental 'E' box)
6ECM (inside 'E' box)
7Fuel Burning Heater (behind wheelarch liner)
'Diesel only'8Cooling Fan Ecu (rear of radiator housing) all
models except 1.8
9ABS ECU (RH side front of engine
compartment)
10Folding door mirror ECU (on transmission
tunnel under centre console)
11Window lift ECU (on driver `A` post)
12Cruise Control Interface ECU (under R/H seat)
13Cruise control ECU (under R/H seat)

PANEL REPAIRS
REPAIRS 77-2-25
REPAIRS
Front bulkhead assembly
In this procedure, the crossmember gusset plates
are replaced in conjunction with the front bulkhead
assembly.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5.Remove front bumper armature.
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 LH and RH headlamps.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
9.Release wiring to headlamps and position
aside.
10.Remove LH and RH engine bay shields.
11.Remove bumper valance LH and RH
attachment brackets.
12.Remove battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
13.Remove air intake hose.
14.Remove horn.

+ SECURITY, REPAIRS, Horn.
15.Remove windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
16.Remove bonnet lock.
17.Support bonnet in open position.
18.Remove bonnet stay. 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.