LAND ROVER FREELANDER 2001 Workshop Manual

AUTOMATIC GEARBOX - JATCO
44-16 REPAIRS
35.Remove 2 top bolts securing gearbox to
engine.
36.Release gearbox from 2 dowels.
37.Remove gearbox assembly.
38.Fit converter retaining plate and secure with
bolts.Refit
1.Remove torque converter retaining plate.
2.Ensure converter is fully located in oil pump
drive by checking depth 'A' as illustrated. Depth
A = 4 mm.
3.Clean gearbox to engine mating faces, dowels
and dowel holes.
4.Fit gearbox assembly.
5.Fit bolts securing gearbox and tighten to 85 Nm
(63 lbf.ft).
6.Disconnect lifting equipment.
7.Clean CKP sensor and mating face.
8.Fit CKP sensor, fit bolt and tighten to 9 Nm (7
lbf.ft).
9.Position fluid cooler, tighten M12 bolts to 85 Nm
(63 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).
10.Connect hoses to fluid cooler.
11.Clean fluid cooler unions.
12.Lubricate new 'O' rings with clean transmission
fluid and fit 'O' rings to fluid cooler hoses.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
13.Connect fluid cooler hoses to gearbox and
tighten unions to 18 Nm (13 lbf.ft).
14.Clean starter motor mating faces.
15.Position starter motor to gearbox, align CKP
sensor multiplug bracket, fit and tighten bolts to
45 Nm (33 lbf.ft).
16.Using gearbox bracket bolts, secure LRT-44-
026 lifting bracket to gearbox.
17.Position IRD cooling hose retainer, fit bolt and
tighten to 25 Nm (18 lbf.ft).
18.Align marks on drive plate to torque converter.
19.Fit bolts securing drive plate to torque converter
and tighten bolts to 45 Nm (33 lbf.ft).
20.Clean torque converter access plate.
M44 1689
A
M44 1668

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
44-18 REPAIRS
8.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release inboard joint
from gearbox.
9.With assistance pull hub outwards and release
drive shaft from gearbox.
CAUTION: Care must be taken not to
damage oil seal when removing drive shaft
from gearbox
10.Remove and discard circlip from drive shaft.11.Remove 2 bolts securing torque converter
access plate.
12.Remove access plate.
13.Mark drive plate to torque converter, for refit
purposes.
14.Remove 4 bolts securing drive plate to
converter.
15.Remove bolt securing IRD cooling hose
retainer. Remove retainer.
M44 1661
M44 1649

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-19
16.Remove 2 bolts securing gearbox to engine.
17.Release HO2S multiplug from support bracket
on LH camshaft cover, disconnect multiplug.
18.Remove 4 nuts securing LH exhaust manifold
to cylinder head.
19.Remove exhaust manifold, remove and discard
gasket.
20.Position container to collect fluid spillage.21.Disconnect 2 fluid cooler hose unions and
discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
22.Remove 3 bolts securing fluid cooler bracket.
23.Move fluid cooler aside.
24.Remove bolt securing CKP sensor to gearbox,
release sensor and position aside.
M44 1651M44 1639
M44 1665

AUTOMATIC GEARBOX - JATCO
44-20 REPAIRS
25.Remove nut and bolt, adjacent to CKP sensor,
securing gearbox to engine.
26.Release throttle cable from abutment bracket
and disconnect cable from throttle body cam, if
fitted.
27.Depress collars and release 2 breather pipes
from throttle housing, if fitted.
28. Vehicles with cruise control: Disconnect
vacuum hose from cruise control actuator.29.Remove 4 Torx screws securing throttle
housing, release throttle housing and position
aside.
Non NAS throttle housing shown.
30.Remove and discard 'O' ring from throttle
housing.
31.Remove starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - KV6.
M19 3198

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-21
32.Remove bolt securing engine earth lead.
33.Release multiplugs from clips attached to fluid
pan.
34.Disconnect 2 gearbox harness to main harness
multiplugs.
35.Using a hoist, connect adjustable lifting
bracket, LRT-12-138 to engine.
36.Raise hoist to take weight without exerting any
load on the engine mountings.37.Fit suitable lifting brackets to gearbox and
secure with nuts and bolts.
38.Connect lifting equipment to brackets.
39.Remove through bolt securing LH engine
mounting to gearbox bracket.
40.Remove 4 bolts securing LH mounting to body
and remove mounting.
41.Remove 4 bolts securing LH mounting bracket
to gearbox and remove bracket.
M12 6789
M12 6788

AUTOMATIC GEARBOX - JATCO
44-22 REPAIRS
42.Remove 2 top bolts securing gearbox to
engine.
43.Release gearbox from 2 dowels.
44.Manoeuvre and lower gearbox to floor.
45.Fit converter retaining plate and secure with
bolts.Refit
1.Remove torque converter retaining plate.
2.Ensure converter is fully located in oil pump
drive by checking depth 'A' as illustrated. Depth
A = 4 mm.
3.Clean gearbox to engine mating faces, dowels
and dowel holes.
4.Fit gearbox assembly.
5.Fit bolts securing gearbox and tighten to 85 Nm
(63 lbf.ft).
6.Position LH mounting bracket to gearbox, fit
and tighten bolts to 85 Nm (63 lbf.ft).
7.Position LH mounting to body, fit and tighten
bolts to 48 Nm (35 lbf.ft).
8.Align gearbox bracket to LH body mounting, fit
and tighten through bolt to 100 Nm (74 lbf.ft).
9.Disconnect lifting equipment.
10.Remove nuts and bolts securing lifting brackets
to gearbox and remove brackets.
11.Connect engine and gearbox harness
multiplugs to main harness.
12.Secure multiplugs to clips.
13.Position engine earth lead and secure with bolt.
14.Fit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - KV6.
15.Clean throttle housing and manifold chamber
mating faces.
16.Fit new seal to inlet manifold chamber.
17.Position throttle housing to manifold chamber,
fit Torx screws and tighten to 7 Nm (7 lbf.ft).
18.Connect throttle inner cable to throttle cam and
secure outer cable in abutment bracket, if fitted.
19.Connect hose to cruise control actuator.
20.Secure breather hoses to throttle housing, if
fitted.
21.Adjust throttle cable, if fitted.

+ FUEL DELIVERY SYSTEM -
PETROL, ADJUSTMENTS, Throttle cable -
check and adjust - KV6.
22.Clean CKP sensor and mating face.
M44 1689
A
M44 1668

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
44-24 REPAIRS
9.Remove and discard circlip from LH drive shaft.
10.Loosen selector cable trunnion nut.
11.Release clip, disconnect selector cable and
remove trunnion.
12.Remove bolt securing closing plate to gearbox.
13.Remove grommet from closing plate to gain
access to torque converter retaining bolts.14.Mark drive plate to torque converter, for refit
purposes.
15.Rotate crankshaft for access and remove 4
bolts securing drive plate to torque converter.
16.Remove bolt and release earth lead from
gearbox.
17.Loosen clip and disconnect hose from
turbocharger outlet pipe.
M44 1681

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-25
18.Release 2 gearbox multiplugs from clips and
disconnect from main harness.
19.Fit lifting chains to lifting eye and take weight of
engine.
20.Remove through bolt, gearbox bracket to LH
mounting.
21.Lower gearbox to clear mounting.22.Remove 4 bolts securing LH mounting bracket
to gearbox and remove bracket.
23.Fit lifting eyes to gearbox and secure with bolts.
24.Fit lifting chains to eye and take weight of
gearbox.
25.Remove 2 bolts securing gearbox to engine.
M44 1682