Starter motor LAND ROVER FREELANDER 2001 Workshop Manual

CONTENTS
CONTENTS 19
WIPERS AND WASHERS ........................................................................ 84-1
REPAIRS
Reservoir - washer ......................................................................................................................... 84-1
Jet - washer - each ........................................................................................................................ 84-2
Pump - washer ............................................................................................................................... 84-2
Arm - wiper - each .......................................................................................................................... 84-3
Blade - wiper - each ....................................................................................................................... 84-3
Motor & linkage - wiper .................................................................................................................. 84-4
Switch - wiper/washer .................................................................................................................... 84-4
Pump - washer ............................................................................................................................... 84-5
Arm - wiper ..................................................................................................................................... 84-5
Blade - wiper .................................................................................................................................. 84-6
Motor - wiper .................................................................................................................................. 84-7
Switch - combined wiper/washer ................................................................................................... 84-8
Relay - tailgate wipe - 5 door ......................................................................................................... 84-8
CHARGING AND STARTING ................................................................... 86-1-1
ADJUSTMENTS
Ancillary drive belt - K1.8 ............................................................................................................... 86-1-1
Ancillary drive belt - K1.8 with A/C .................................................................................................. 86-1-2
REPAIRS
Alternator - Td4 ............................................................................................................................... 86-1-3
Alternator - KV6 .............................................................................................................................. 86-1-5
Alternator - K1.8 .............................................................................................................................. 86-1-6
Ancillary drive belt - Td4 ................................................................................................................. 86-1-7
Ancillary drive belt - K1.8 without A/C ............................................................................................. 86-1-8
Ancillary drive belt - K1.8 with A/C .................................................................................................. 86-1-9
Ancillary drive belt - KV6 ................................................................................................................. 86-1-10
Tensioner - ancillary drive belt - Td4 ............................................................................................... 86-1-11
Battery ............................................................................................................................................. 86-1-12
Carrier - battery ............................................................................................................................... 86-1-13
Relay - main .................................................................................................................................... 86-1-14
Starter motor - Td4 .......................................................................................................................... 86-1-15
Starter motor - KV6 ......................................................................................................................... 86-1-16
Starter motor - K1.8 ........................................................................................................................ 86-1-17
Relay - starter ................................................................................................................................. 86-1-18

TORQUE WRENCH SETTINGS
06-22
Automatic Gearbox – Jatco
†Tighten in sequence.
+ Apply sealant, Part No. STC 4600 to threads
TORQUE DESCRIPTION METRIC IMPERIAL
Air blast cooler assembly to chassis bolts:
⇒ Lower10 Nm 7.5 lbf.ft
⇒ Upper5 Nm 3.5 lbf.ft
Air blast cooler fan cowl to matrix bolts 5 Nm 3.5 lbf.ft
Air blast cooler fan motor to cowl bolts 5 Nm 3.5 lbf.ft
Air blast cooler multiplug mounting bracket nut 10 Nm 7.5 lbf.ft
Air blast cooler pipe union nuts 25 Nm 18 lbf.ft
Crankshaft Position (CKP) Sensor 9 Nm 7 lbf.ft
Closing panel to gearbox panel bolt 10 Nm 7.5 lbf.ft
Drive plate to converter bolts 45 Nm 33 lbf.ft
Earth lead to gearbox housing bolt 25 Nm 18 lbf.ft
Fluid cooler to mounting bracket bolts (KV6) 25 Nm 18 lbf.ft
Fluid cooler mounting bracket bolts (KV6):
⇒ M825 Nm 18 lbf.ft
⇒ M1285 Nm 63 lbf.ft
Fluid cooler mounting bolts (Td4):
⇒ 2 off45 Nm 33 lbf.ft
⇒ 1 off25 Nm 18 lbf.ft
Fluid cooler hoses to gearbox 18 Nm 13 lbf.ft
Fluid cooler hose unions 18 Nm 13 lbf.ft
Fluid pan bolts
† +7 Nm 5 lbf.ft
Gearbox closing plate bolt (Td4) 10 Nm 7.5 lbf.ft
Gearbox drain plug 45 Nm 33 lbf.ft
Gearbox level plug 14 Nm 10 lbf.ft
Gearbox housing to sump 85 Nm 63 lbf.ft
Gearbox to engine bolts 85 Nm 63 lbf.ft
Gearbox mounting bracket bolts 85 Nm 63 lbf.ft
Gearbox mounting through bolt 100 Nm 74 lbf.ft
Inhibitor switch bolts 3 Nm 2.2 lbf.ft
IRD cooling hose retainer bolt (KV6) 25 Nm 18 lbf.ft
IRD support bracket mounting bolts
† (KV6) 50 Nm 37 lbf.ft
IRD support bracket to engine front mounting bracket bolts
† (KV6) 50 Nm 37 lbf.ft
IRD support bracket to sump bolts
† (KV6) 45 Nm 33 lbf.ft
IRD to gearbox bolts (KV6) 80 Nm 59 lbf.ft
Manifold heatshield to IRD support bracket (KV6):
⇒ Bolts9 Nm 7 lbf.ft
⇒ Nut45 Nm 33 lbf.ft
Manifold heatshield to IRD pinion housing nut (KV6) 25 Nm 18 lbf.ft
Selector housing nuts 10 Nm 7.5 lbf.ft
Selector cable trunnion nut 6 Nm 4.5 lbf.ft
Selector lever to gearbox selector shaft nut 25 Nm 18 lbf.ft
Starter motor to gearbox bolts 45 Nm 33 lbf.ft
Torque converter access plate bolts 9 Nm 7 lbf.ft

TORQUE WRENCH SETTINGS
06-35
Electrical
TORQUE DESCRIPTION METRIC IMPERIAL
Alternator drive belt tensioner bolt 25 Nm 18 lbf.ft
Alternator mounting bracket bolts (K1.8) 25 Nm 18 lbf.ft
Alternator pivot and adjustment bracket bolts (K1.8) 25 Nm 18 lbf.ft
Alternator to front mounting plate nut and bolts (KV6) 45 Nm 33 lbf.ft
Alternator support bracket bolts (K1.8) 25 Nm 18 lbf.ft
Alternator pivot and adjustment bracket bolts (K1.8) 25 Nm 18 lbf.ft
Alternator to mounting bracket bolts (Td4):
⇒ M825 Nm 18 lbf.ft
⇒ M1045 Nm 9.5 lbf.ft
Alternator upper and lower bolts (K1.8 with A/C) 45 Nm 33 lbf.ft
Ancillary drive belt idler pulley to mounting Allen bolt (Td4) 25 Nm 18 lbf.ft
Battery cable to alternator terminal nut (Td4 & KV6) 10 Nm 7.5 lbf.ft
Battery cable to starter motor solenoid nut (K1.8) 8 Nm 6 lbf.ft
Battery cable to starter motor solenoid nut (K1.8) 13 Nm 9.5 lbf.ft
Battery clamp bolt 12 Nm 9 lbf.ft
Battery and starter motor lead to underbonnet fusebox bolts 8 Nm 6 lbf.ft
'E' box mounting nut 9 Nm 7 lbf.ft
Passenger compartment fusebox mounting plate to body bolts 8 Nm 6 lbf.ft
Passenger compartment fusebox to mounting plate bolts 8 Nm 6 lbf.ft
Starter motor mounting bolts (Td4) 45 Nm 33 lbf.ft
Starter motor to engine upper and lower nuts and bolts (K1.8) 45 Nm 33 lbf.ft
Starter motor to engine upper and lower nuts and bolts (K1.8) 80 Nm 59 lbf.ft

ENGINE - K SERIES KV6
12-3-34 REPAIRS
38.With assistant depressing the brake pedal,
tighten front hub nuts to 400 Nm (295 lbf.ft).
39.Stake nut to shaft.
40.Fit front road wheels, fit and tighten nuts to 115
Nm (85 lbf.ft).
41.Lower vehicle on ramp.
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, if fitted.
48.Secure throttle cable in clips on harness
brackets, if fitted.
49.Adjust throttle cable, if fitted.

+ FUEL DELIVERY SYSTEM -
PETROL, ADJUSTMENTS, Throttle cable -
check and adjust - KV6.
50.Connect hose to purge control valve.
51.Connect fuel hose to fuel rail pipe, fit rubber
sleeve over hose connector.
52.Connect gearbox harness multiplugs and
secure multiplugs in mounting bracket clips.
53.Connect Lucar connector to starter solenoid.
54.Position earth lead to gearbox housing, fit and
tighten bolt to 25 Nm (18 lbf.ft).
55.Position engine harness to 'E' box mounting
bracket and secure with clips.
56.Connect earth header multiplug.
57.Connect multiplug to underbonnet fuse box.
58.Position battery and starter motor lead to
underbonnet fuse box, fit and tighten bolts to 8
Nm (6 lbf.ft).
59.Fit underbonnet fuse box cover.
60.Position 'E' box, secure in retaining clip, fit and
tighten nut to 9 Nm (7 lbf.ft).
61.Position carrier in 'E' box and secure with clips.
62.Position and secure air duct and harness
rubber sleeve in 'E' box.
63.Connect multiplugs securing main harness to
engine harness.
64.Position ECM harness and multiplug to 'E' box,
align harness clamp and secure screws to 'E'
box.
65.Fit engine ECM.

+ ENGINE MANAGEMENT SYSTEM -
SIEMENS, REPAIRS, Engine control module
(ECM) - Non NAS.
66.Fit battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.67.Fill cooling system.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
68.Connect battery earth lead.
69.Fill gearbox with fluid.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
70.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.

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.

AUTOMATIC GEARBOX - JATCO
44-14 REPAIRS
18.Remove 2 bolts securing torque converter
access plate.
19.Remove access plate.
20.Mark drive plate to torque converter, for refit
purposes.
21.Remove 4 bolts securing drive plate to
converter.
22.Remove bolt securing IRD cooling hose
retainer. Remove retainer.23.Remove bolts securing LRT-44-026 lifting
bracket to gearbox and remove bracket.
24.Remove 3 bolts securing starter motor to
gearbox noting that the LH bolt also secures
the mounting bracket for the CKP sensor
multiplug.
25.Remove starter motor.
M44 1661
M44 1649

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
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
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.