cooling LAND ROVER FREELANDER 2001 Repair Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 2001, Model line: FREELANDER, Model: LAND ROVER FREELANDER 2001Pages: 1007, PDF Size: 23.47 MB
Page 792 of 1007
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.
Page 793 of 1007
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.
Page 872 of 1007
HEATING AND VENTILATION
REPAIRS 80-7
Heater unit
$% 80.20.01
Remove
1.Drain cooling system.
+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.
+ COOLING SYSTEM - K SERIES 1.8,
ADJUSTMENTS, Coolant - drain & refill.
+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
2.Release 2 clips securing heater hoses to heater
and disconnect hoses.
3.Remove fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
4.Remove 2 bolts from console support bracket,
release 2 relays and remove bracket. Up to
03MY illustrated.5.Disconnect 4 multiplugs from heater controls.
Up to 04MY illustrated.
6.Disconnect multiplug from heater and release
diagnostic socket.
7. Models with A/C: Disconnect multiplug from
evaporator.
8.Remove bolt from duct of LH outer face level
vent and release duct from heater.
Page 874 of 1007
HEATING AND VENTILATION
REPAIRS 80-9
Refit
1.Position heater controls to replacement heater.
2.Connect air distribution cable to lever and
abutment.
3.Connect air blend cable to lever and abutment.
4.Connect multiplugs to heater controls.
5.Fit heater and secure with nuts and bolt.
6.Position harness and connect to clips on
heater.
7.Fit air inlet connector hose.
8.Fit RH demister vent duct to heater.
9. Models with passenger airbag, fit carrier.Fit
RH outer face level vent duct to heater and
secure to body with bolt.
10.Fit LH demister vent duct to heater.
11.Fit LH outer face level vent duct to heater and
secure to body with bolt.
12. Models with A/C: Connect multiplug to
evaporator.
13.Connect multiplug to heater and secure
diagnostic socket.
14.Connect multiplugs to heater controls.
15.Fit console support bracket and secure with
bolts.
16.Fit relays to console support bracket.
17.Fit fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
18.Connect heater hoses and secure with clips.
19.Refill cooling system.
+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.
+ COOLING SYSTEM - K SERIES 1.8,
ADJUSTMENTS, Coolant - drain & refill.
+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
Page 876 of 1007
HEATING AND VENTILATION
REPAIRS 80-11
Harness - positive temperature co-
efficient (PTC) heater - Td4 models
$% 80.20.06
Remove
1.Disconnect battery earth lead.
2.Remove bolt securing PTC cable from positive
side of battery.
3.Remove ECM from 'E' box.
+ ENGINE MANAGEMENT SYSTEM -
EDC, REPAIRS, Engine control module
(ECM).
4.Disconnect multiplugs from gearbox ECU and
cooling fan sensor5.Release harness from cable ties and release
relays from inner casing.
6.Release and disconnect cooling fan and joint
harness multiplugs.
7.Release 3 harnesses and air duct rubber
sleeve's from housing.
8.Release clips and remove fuse box cover.
9.Remove nut securing ECM housing.
10.Release housing from retaining brackets and
remove.
M80 0557
Page 878 of 1007
HEATING AND VENTILATION
REPAIRS 80-13
21.Disconnect 3 Lucar connections from PTC
element.
22.Release cable ties securing PTC harness to
main harness.
23.Remove air intake plenum.
+ HEATING AND VENTILATION,
REPAIRS, Plenum - air intake.
24.Release 2 clips securing PTC harness from
plenum box section.
25.With assistance release 2 grommets from
bulkhead and remove PTC harness from
vehicle.Refit
1.With assistance route PTC harness through
bulkhead and fit grommets.
2.Fit clips securing PTC harness to plenum box
3.Fit air intake plenum.
+ HEATING AND VENTILATION,
REPAIRS, Plenum - air intake.
4.Fit cable ties securing PTC harness to main
bulkhead harness.
5.Connect Lucar connections to PTC element.
6.Fit air duct.
7.Fit RH demister vent duct.
8.Fit fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
9.Connect and secure PTC harness multiplug to
engine harness.
10.Secure PTC harness/relay to bulkhead bracket
11.Fit clip to secure PTC harness to ECM housing
bracket.
12.Fit PTC positive leads to (80 amp) fuse holder,
fit and tighten nuts to 7 Nm (5.2 lbf.ft).
13.Fit (80 amp) fuse cover.
14.Secure PTC harness/relays to ECM housing
bracket.
15.Fit fuse box, ensure harness routing is clear
suspension turret. Tighten nuts to 10 Nm (7
lbf.ft).
16.Fit fuse box cover.
17.Fit 'E' box housing into securing brackets.
18.Fit and tighten nut securing housing.
19.Fit harness and air duct rubber sleeve's to
housing.
20.Fit harness cable tie and secure relay in
housing.
21.Connect and secure joint harness and cooling
fan multiplugs.
22.Connect cooling fan sensor and gearbox ECU
multiplugs.
23.Fit ECM into 'E' box.
+ ENGINE MANAGEMENT SYSTEM -
EDC, REPAIRS, Engine control module
(ECM).
24.Position PTC positive cable to battery and
secure with bolt, tighten to 25 Nm (18 lbf.ft).
25.Connect battery earth lead.
Page 883 of 1007
HEATING AND VENTILATION
80-18REPAIRS
Fuel burning heater (FBH)
$% 80.40.01
Remove
1.Disconnect battery earth lead.
2.Remove front bumper.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
3.Drain coolant.
+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.
4.Position container to collect coolant spillage.
5.Release clips, disconnect coolant feed and
return hoses from FBH.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
6.Position an absorbent cloth, release clip and
remove fuel feed hose from FBH. Plug
connections and move aside.7.Loosen 1 bolt and remove other bolt securing
FBH mounting bracket to body.
8.Release FBH from mounting, disconnect
multiplugs and move assembly aside.
NOTE: Do not carry out further dismantling if
component is removed for access only.
9.Remove 3 bolts securing FBH to mounting
bracket.
10.Remove bracket.
M80 0496
M80 0499
Page 884 of 1007
HEATING AND VENTILATION
REPAIRS 80-19
11.Release clip securing air intake hose to FBH,
release clamp from exhaust manifold.
12.Remove 2 bolts securing air intake and exhaust
assembly to FBH and move aside.
Refit
1.Fit exhaust pipe, air intake hose and bracket
assembly to FBH.
2.Fit and tighten bolts to 10 Nm (7.5 lbf.ft).
3.Tighten exhaust pipe clamp to 5 Nm (3.5 lbf.ft).
4.Align air intake hose with mark on casing and
secure with clip.
5.Fit mounting bracket to FBH and tighten bolts to
10 Nm (7.5 lbf.ft).
6.Connect multiplugs to FBH.
7.Fit FBH to body, tighten bolts to 10 Nm (7.5
lbf.ft).
8.Fit coolant hoses to FBH and secure with clips.
9.Fit fuel feed hose to FBH and secure with clip.
10.Refill cooling system.
+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.
11.Fit front bumper.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
12.Connect battery earth lead.
Sensor - outside temperature (OT)
$% 80.40.31
Remove
1.Remove front bumper.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
2.Disconnect multiplug from OT sensor.
3.Remove OT sensor from mounting bracket,
collect rubber washer and spacer.
Refit
1.Clean OT mounting bracket and sensor.
2.Fit OT sensor to mounting bracket, fit rubber
washer and spacer, connect multiplug.
3.Fit front bumper.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
Page 916 of 1007
CHARGING AND STARTING
REPAIRS 86-1-3
REPAIRS
Alternator - Td4
$% 86.10.02
Remove
1.Disconnect battery earth lead.
2.Drain cooling system.
+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.
3. Models with A/C: Remove compressor drive
belt.
+ AIR CONDITIONING, REPAIRS,
Drive belt - compressor - Td4.
4.Remove 3 bolts securing coolant rail to sump
and cylinder block.
CAUTION: Care must be taken to ensure
that oil or fluid does not enter or
contaminate the alternator.
5. Models with A/C: Loosen bolt securing
compressor support bracket to sump, do not
remove.
6. Models with A/C: Remove 3 bolts securing
compressor to mounting bracket, release
support bracket and tie compressor aside.7. Models with A/C: Remove 3 bolts and bracket,
securing compressor mounting to casting on
cylinder block.
8.Disconnect alternator multiplug.
9.Remove nut securing battery cable to alternator
and remove cable.
10.Remove 3 bolts and remove alternator.
M86 5309
M86 5311
Page 917 of 1007
CHARGING AND STARTING
86-1-4 REPAIRS
Refit
1.Clean alternator mounting points.
2.Fit alternator to mounting bracket.Tighten M10
bolt to 45 Nm (33 lbf.ft) and M8 bolts to 25 Nm
(18 lbf.ft).
CAUTION: Ensure upper bolt is fitted prior
to assembly.
3.Connect alternator multiplug.
4.Fit battery cable to alternator terminal and
tighten to 10 Nm (7.5 lbf.ft).
5. Models with A/C: Clean A/C compressor and
housing mating faces, dowels and dowel holes.
6. Models with A/C: Fit bolts and compressor
mounting to casting, tighten to 25 Nm (18 lbf.ft).
7. Models with A/C: Position A/C compressor, fit
bolts and tighten to 25 Nm (18 lbf.ft).
8. Models with A/C: Align compressor support
bracket to sump and tighten bolt to 10 Nm (7.5
lbf.ft).
9.Fit lower coolant rail to sump and tighten bolts
to 10 Nm (7.5 lbf.ft).
10.Fit compressor drive belt.
+ AIR CONDITIONING, REPAIRS,
Drive belt - compressor - Td4.
11.Refill cooling system.
+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.
12.Connect battery earth lead.