door lock LAND ROVER FREELANDER 2001 Workshop 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 7 of 1007
CONTENTS
4CONTENTS
MAINTENANCE ........................................................................................ 10-1
MAINTENANCE
Td4 - Diesel Engine - Under Bonnet View ...................................................................................... 10-1
K1.8 – Petrol Engine – Under Bonnet View .................................................................................... 10-2
KV6 – Petrol Engine – Under Bonnet View .................................................................................... 10-3
Seats and Seat Belts ...................................................................................................................... 10-4
Lamps, Horns and Warning Indicators ........................................................................................... 10-4
Wipers and Washers ...................................................................................................................... 10-5
Handbrake ...................................................................................................................................... 10-5
Alarm Handset Battery.................................................................................................................... 10-6
Road Wheels .................................................................................................................................. 10-6
Tyres ............................................................................................................................................... 10-7
Brake Pads and Calipers ................................................................................................................ 10-7
Brake Fluid...................................................................................................................................... 10-9
Road Wheel Speed Sensors .......................................................................................................... 10-9
Fuel Filter - Petrol ........................................................................................................................... 10-10
Fuel Filter - Diesel........................................................................................................................... 10-10
Fuel Pump and Filter assembly - Diesel - 03 Model Year onwards ................................................ 10-10
Fuel Sedimenter - Diesel - 03 Model Year onwards ....................................................................... 10-10
Door Locks, Hinges, Check Straps and Bonnet Catch ................................................................... 10-11
Anti-freeze ...................................................................................................................................... 10-12
Cooling System and Intercooler...................................................................................................... 10-12
Vent filter - turbocharger boost control solenoid valve - Td4 .......................................................... 10-13
Spark Plugs – K1.8 ......................................................................................................................... 10-13
Spark Plugs – KV6.......................................................................................................................... 10-13
Air Cleaner – Petrol Models ............................................................................................................ 10-13
Ancillary Drive Belt – Td4 ............................................................................................................... 10-14
Ancillary Drive Belt – K1.8 .............................................................................................................. 10-14
Ancillary Drive Belt – KV6 ............................................................................................................... 10-15
Camshaft Timing Belt – K1.8 .......................................................................................................... 10-15
Camshaft Timing Belt – KV6........................................................................................................... 10-16
Brake/Clutch Reservoir ................................................................................................................... 10-16
PAS Fluid Level .............................................................................................................................. 10-17
Intermediate Reduction Drive - Non NAS models .......................................................................... 10-17
Intermediate Reduction Drive - NAS models .................................................................................. 10-18
Manual Gearbox – PG1 .................................................................................................................. 10-18
Manual Gearbox – GETRAG .......................................................................................................... 10-19
Automatic Gearbox – JATCO ......................................................................................................... 10-19
Rear Axle ........................................................................................................................................ 10-20
Clutch Pipes and Unions ................................................................................................................ 10-21
Windscreen and Rear Washer Reservoir ....................................................................................... 10-21
Battery ............................................................................................................................................ 10-21
Engine Oil and Filter – Td4 ............................................................................................................. 10-22
Engine Oil and Filter – K1.8 ............................................................................................................ 10-23
Engine Oil and Filter – KV6 ............................................................................................................ 10-24
Fuel Hoses and Pipes..................................................................................................................... 10-25
Brake Hoses and Pipes ................................................................................................................. 10-26
Check Exhaust System................................................................................................................... 10-26
Suspension ..................................................................................................................................... 10-27
Steering ......................................................................................................................................... 10-28
Road Test ....................................................................................................................................... 10-28
Endorse Service Record ................................................................................................................. 10-30
Report any Unusual Features ......................................................................................................... 10-30
Page 16 of 1007
CONTENTS
CONTENTS 13
Remote control - front door ............................................................................................................. 76-1-30
Remote control - rear door .............................................................................................................. 76-1-30
Operating cable - lock remote control - 5 door ............................................................................... 76-1-31
Finisher - rear screen - side - 5 door .............................................................................................. 76-1-31
Handle - exterior - rear door ........................................................................................................... 76-1-32
Handle - exterior - tail door ............................................................................................................. 76-1-33
Handle - exterior - front door ........................................................................................................... 76-1-34
Door pull - 5 door - up to 04MY ....................................................................................................... 76-1-35
EXTERIOR FITTINGS ............................................................................... 76-2-1
REPAIRS
Wing - front ..................................................................................................................................... 76-2-1
Liner - front wheel arch ................................................................................................................... 76-2-2
Liner - rear wheel arch .................................................................................................................... 76-2-3
Panel - underbelly ........................................................................................................................... 76-2-4
Mirror - exterior - electric ................................................................................................................. 76-2-4
Mud flap - front ................................................................................................................................ 76-2-5
Mud flap - rear ................................................................................................................................. 76-2-5
Bracket - spare wheel mounting ..................................................................................................... 76-2-6
Side rail - integral roof rack - 5 door ................................................................................................ 76-2-7
Bonnet............................................................................................................................................. 76-2-7
Cable/rod - bonnet lock control ....................................................................................................... 76-2-8
Bumper - assembly - front - up to 04MY ......................................................................................... 76-2-10
Bumper - assembly - front - from 04MY .......................................................................................... 76-2-11
Bumper valance - rear - up to 04MY ............................................................................................... 76-2-13
Bumper valance - rear - from 04MY ................................................................................................ 76-2-13
Finisher - sill - lower ....................................................................................................................... 76-2-16
Moulding - roof - 5 door ................................................................................................................... 76-2-17
Wheelarch extension - rear wing part ............................................................................................. 76-2-18
Body quarter vent assembly - 3 door .............................................................................................. 76-2-19
Page 19 of 1007
CONTENTS
16 CONTENTS
PANEL REPAIRS...................................................................................... 77-2-1
BODY REPAIRS
General ........................................................................................................................................... 77-2-1
REPLACEMENT PANELS
Serviceable Panels ......................................................................................................................... 77-2-3
Inner front end panels ..................................................................................................................... 77-2-4
Outer body side panels - 3 door ..................................................................................................... 77-2-5
Outer body side panels - 5 door ..................................................................................................... 77-2-6
Front inner body side panels - 3 door ............................................................................................. 77-2-7
Front inner body side panels - 5 door ............................................................................................. 77-2-8
Rear inner body side panels - 3 door.............................................................................................. 77-2-9
Rear inner body side panels - 5 door.............................................................................................. 77-2-10
Roof assemblies - 3 door ................................................................................................................ 77-2-11
Roof assembly - 5 door................................................................................................................... 77-2-12
Rear end panels ............................................................................................................................. 77-2-13
Door assemblies ............................................................................................................................. 77-2-14
WELDING PROCEDURES
ECU locations (3 door model shown, 5 door model similar) ........................................................... 77-2-15
General Welding Precautions ......................................................................................................... 77-2-16
PROCEDURES
Panel replacement procedure......................................................................................................... 77-2-19
REPAIRS
Front bulkhead assembly ............................................................................................................... 77-2-25
Bonnet locking platform .................................................................................................................. 77-2-27
Headlamp mounting panel .............................................................................................................. 77-2-28
Front lower crossmember .............................................................................................................. 77-2-29
Front sidemember (complete) ........................................................................................................ 77-2-30
Front sidemember (front section) ................................................................................................... 77-2-32
Front valance assembly ................................................................................................................. 77-2-33
Valance upper front ....................................................................................................................... 77-2-36
Valance front .................................................................................................................................. 77-2-37
Valance outer reinforcement .......................................................................................................... 77-2-39
'A' post - 3 door .............................................................................................................................. 77-2-40
'A' post - 5 door .............................................................................................................................. 77-2-41
Sill reinforcement - 3 door .............................................................................................................. 77-2-43
Sill reinforcement - 5 door .............................................................................................................. 77-2-44
'B/C' post reinforcement - 3 door ................................................................................................... 77-2-45
'B/C' post reinforcement - 5 door ................................................................................................... 77-2-46
Complete rear quarter - 3 door ...................................................................................................... 77-2-48
Complete rear quarter - 5 door ...................................................................................................... 77-2-50
Outer rear wheel arch - 3 door ....................................................................................................... 77-2-53
Outer rear wheel arch - 5 door ....................................................................................................... 77-2-54
Inner 'e' post - 3 door ..................................................................................................................... 77-2-55
Inner 'e' post - 5 door ..................................................................................................................... 77-2-56
Rear floor crossmember assembly ................................................................................................ 77-2-58
Rear floor ........................................................................................................................................ 77-2-59
Floor longitudinal ............................................................................................................................ 77-2-60
Front roof assembly - 3 door .......................................................................................................... 77-2-61
Rear roof assembly - 3 door .......................................................................................................... 77-2-61
Roof assembly - 5 door .................................................................................................................. 77-2-62
TIMES
TIME SCHEDULES ........................................................................................................................ 77-2-63
Page 28 of 1007
INTRODUCTION
01-3
Abbreviations and Symbols
A Amperes
AAP Ambient Air Pressure
AAT Ambient Air Temperature
ABDC After Bottom Dead Centre
ABS Anti-Lock Brake System
ABS / TC Anti-lock Brake System / Traction
Control
ac Alternating current
A/C Air Conditioning
ACE Active Cornering Enhancement
ACEA Association of Constructors of
European Automobiles
AFR Air Fuel Ratio
AP Ambient Pressure
ASC Anti-shunt Control
ATC Air Temperature Control
ATDC After Top Dead Centre
AUX Auxiliary
AVC Automatic Volume Control
BBDC Before Bottom Dead Centre
BBUS Battery Backed Up Sounder
BCU Body Control Unit
BDC Bottom Dead Centre
bhp Brake Horse Power
BP Boost Pressure
BPP Brake Pedal Position
BS British Standard
BTDC Before Top Dead Centre
BWD Backward
C Celsius
CAN Controller Area Network
CD Compact Disc
CDC Centre Differential Control
CDL Central Door Locking
CD - ROM Compact Disc - Read Only
Memory
CFC Chlorofluorocarbon
CHMSL Centre High Mounted Stop Lamp
CKP Crankshaft Position
CLV Calculated Load Value
cm Centimetre
cm
2Square centimetre
cm3Cubic centimetre
CMP Camshaft Position
CPP Clutch Pedal Position
CO Carbon Monoxide
CO
2Carbon Dioxide
COB Clear Over Base
CR Common Rail
CVS Canister Vent Solenoid
dB Decibels
DDM Driver's Door Module
deg. Degree, angle or temperature
DI Direct Injection
dia. DiameterDIN Deutsche Industrie Normen
(German Industrial Standards)
dc Direct current
DCV Directional Control Valve
DOHC Double Overhead Camshaft
DSP Digital Signal Processing
DTI Dial Test Indicator
DMF Dual Mass Flywheel
DVD Digital Versatile Disc
EACV Electronic Air Control Valve
EAT Electronic Automatic
Transmission
EBD Electronic Brake pressure
Distribution
ECD European Community Directive
ECM Engine Control Module
ECT Engine Coolant Temperature
ECU Electronic Control Unit
EDC Electronic Diesel Control
EEPROM Electronic Erasable
Programmable Read Only
Memory
EGR Exhaust Gas Recirculation
EKA Emergency Key Access
ELR Emergency Locking Retractor
EN European Norm
EOBD European On Board Diagnostics
EON Enhanced Other Network
ERL Electrical Reference Library
ETC Electronic Traction Control
EUI Electronic Unit Injector
EVAP Evaporative Emission
EVR Electronic Vacuum Regulator
F Fahrenheit
ft. Feet
FBH Fuel Burning Heater
FET Field Effect Transistor
FIP Fuel Injection Pump
FTC Fast Throttle Control
FWD Forward
> Greater than
g Gramme or Gravity
gal. Gallons
GMT Greenwich Mean Time
GPS Global Positioning System
hHour
hc High compression
HC Hydro Carbons
HDC Hill Descent Control
HDOP Height Dilation Of Precision
HDPE High Density Polyethylene
HFS Heated Front Screen
Hg Mercury
HO
2S Heated Oxygen Sensor
HMW High Molecular Weight
Page 101 of 1007
IDENTIFICATION NUMBERS
05-2
Vehicle identification number -
Example: SALLNABG11A518779
Paint and trim colour codes
Paint code (F): a 3 digit code identifying the original
paint colour is stamped on the VIN plate.
Trim code (G):a code identifying the original trim
type and colour is stamped on the VIN plate.
Identification Number Locations
Engine number
K1.8 engine serial number is stamped on the front
face of the cylinder block adjacent to the gearbox.
K1.8 engines
KV6 engine serial number is stamped on the rear LH
side of the LH cylinder block.
KV6 engines
Td4 engine serial number is stamped on the bottom
LH side of the cylinder block.SALManufacturer's identifier (Land Rover UK)
LNMarque/Model
LN = Freelander
ATrim level
A = Trim level 1
BBody Style
B = 5 door models
GEngine
G = KV6 petrol engine models
1Transmission and Steering
1 = RHD automatic gearbox
1Model Year
1 = 2001 Model year
2 = 2002 Model year
3 = 2003 Model year
AAssembly plant
A = Solihull
6 figures= Serial number
Page 133 of 1007
TORQUE WRENCH SETTINGS
06-30
Body
TORQUE DESCRIPTION METRIC IMPERIAL
Doors
Door lock striker to body screws 10 Nm 7 lbf.ft
Door stiffener Torx screws 9 Nm 7 lbf.ft
Front door control unit to glass clamp bolts 9 Nm 7 lbf.ft
Front door hinge bolts 30 Nm 22 lbf.ft
Rear door glass clamp bolts 8 Nm 6 lbf.ft
Tail door exterior handle nuts 5 Nm 3.7 lbf.ft
Tail door glass clamp bolts 8 Nm 6 lbf.ft
Tail door glass regulator lock nuts 14 Nm 10 lbf.ft
Tail door hinge bolts 30 Nm 22 lbf.ft
Exterior Fittings
Bonnet hinge, bolts 9 Nm 6.5 lbf.ft
Bonnet release lever to 'A' post bolt 9 Nm 6.5 lbf.ft
Exterior mirror to door Torx screws 6 Nm 4.4 lbf.ft
Front wing bolts5 Nm 3.7 lbf.ft
Spare wheel mounting bracket:
⇒ Bolts13 Nm 10 lbf.ft
⇒ Nuts25 Nm 18 lbf.ft
Spare wheel to bracket retention nuts 45 Nm 33 lbf.ft
Splash shield bolts 10 Nm 7 lbf.ft
Underbelly panel to body bolts 45 Nm 33 lbf.ft
Underbelly panel to body rear screws 8 Nm 6 lbf.ft
3 door vehicles
Hard back catch Torx screws 10 Nm 7.5 lbf.ft
Hard back retainer Torx screws 10 Nm 7.5 lbf.ft
Soft back support bracket bolts 25 Nm 18 lbf.ft
5 door vehicles
Roof rack side rail bolts 22 Nm 16 lbf.ft
Interior Trim Components
Engine compartment fusebox bolts 8 Nm 6 lbf.ft
Passenger compartment fusebox mounting plate to body and steering column
bracket bolts8 Nm 6 lbf.ft
Passenger compartment fusebox to mounting plate bolts 8 Nm 6 lbf.ft
Seats
Front seat runner to body bolts 45 Nm 33 lbf.ft
Front seat squab frame to cushion frame Torx bolts 45 Nm 33 lbf.ft
Rear bench seat to body bolts 25 Nm 18 lbf.ft
Rear seat cushion to squab Torx bolts 28 Nm 21 lbf.ft
Rear seat catch assembly Torx bolts 32 Nm 24 lbf.ft
Rear seat squab lock Torx screws 20 Nm 15 lbf.ft
Rear seat squab to cushion Torx bolts 28 Nm 21 lbf.ft
Rear seat hinge Torx bolts 25 Nm 18 lbf.ft
Page 134 of 1007
TORQUE WRENCH SETTINGS
06-31
Seat belts (3-door models)
Front seat belt loop to 'B' post bolt 31 Nm 23 lbf.ft
Front seat belt pre-tensioner and buckle to seat frame Torx bolt 32 Nm 24 lbf.ft
Front seat belt reel bolt 31 Nm 23 lbf.ft
Front seat belt slider bar bolts 40 Nm 30 lbf.ft
Front seat belt lower mounting Torx bolts 40 Nm 30 lbf.ft
Front seat belt upper mounting Torx bolt 31 Nm 23 lbf.ft
Rear seat belt and buckle to frame Torx bolts 32 Nm 24 lbf.ft
Rear seat belt lower fixing to body bolt 50 Nm 37 lbf.ft
Rear seat belt reel to squab nut 32 Nm 24 lbf.ft
Rear seat belt upper mounting bolt 32 Nm 24 lbf.ft
Rear seat squab lock Torx screws 20 Nm 15 lbf.ft
Seat belt pre-tensioner to seat bolt 32 Nm 24 lbf.ft
Seat belts (5-door models)
Front seat belt adjuster to 'B' post Torx bolts 26 Nm 19 lbf.ft
Front seat belt upper anchorage to adjuster mounting nut 31 Nm 23 lbf.ft
Front seat belt lower fixing to 'B' post bolt 40 Nm 30 lbf.ft
Front seat belt pre-tensioner and buckle to seat frame Torx bolt 32 Nm 24 lbf.ft
Front seat belt reel bolt 31 Nm 23 lbf.ft
Rear centre seat belt reel to seat squab nut 32 Nm 24 lbf.ft
Rear seat belt and buckle bolts 32 Nm 24 lbf.ft
Rear side seat belt lower fixing bolt 40 Nm 30 lbf.ft
Rear side seat belt reel bolt 50 Nm 37 lbf.ft
Rear side seat belt buckle to catch assembly bolt 32 Nm 24 lbf.ft
Rear side seat belt upper mounting bolt 32 Nm 24 lbf.ft
Seat belt height adjuster bolts 26 Nm 19 lbf.ft
Screens
Sun roof side rail Torx bolts 22 Nm 16 lbf.ft TORQUE DESCRIPTION METRIC IMPERIAL
Page 158 of 1007
MAINTENANCE
MAINTENANCE 10-11
Door Locks, Hinges, Check Straps and
Bonnet Catch
Check
1.Check operation of each door, door lock,
bonnet catch and fuel filler flap.Lubricate Front and Rear Doors
1.Open each door in turn and lubricate door
hinges and check strap using recommended
lubricant.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
2.Lubricate door lock, striker and private lock
using PTFE lubricant. Remove excessive
lubricant, particularly from door striker area, to
avoid customer complaint.
3.Check tightness of accessible door lock and
striker fixings.
4.Open and close door to check for smooth,
noise-free operation. Ensure door closes
securely.
5.Check for smooth operation of private lock.
Lubricate Tail Door
1.Open tail door and lubricate hinges using
recommended lubricant.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
2.Grease tail door check slide.
3.Lubricate rear door lock and striker using PTFE
lubricant. Remove excessive lubricant to avoid
customer complaint, particularly from door
striker area.
4.Check tightness of accessible tail door lock and
striker fixings.
Lubricate Bonnet
1.With bonnet open, lubricate hinges, striker, lock
and safety catch using a suitable lubricant.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
Sunroof Guide Rails, Slides and Seal
1.With sunroof open, lubricate accessible guide
rails, slides and seals. Remove any excess
lubricant to avoid contaminating roof lining and
trim.
2.Ensure sunroof closes correctly.
Sunroof Drain Tubes and Channels
1.Remove any debris from sunroof tray.
2.Ensure that all accessible sunroof drain tubes
are clear using a low pressure air line.
Page 350 of 1007
FUEL DELIVERY SYSTEM - PETROL
REPAIRS 19-2-29
Pump - fuel
$% 19.45.08
WARNING: If fuel tank is full, using a fuel
recovery appliance, drain excess fuel from fuel
filler neck until a level below height of fuel pump
is obtained.
Remove
1.Disconnect battery earth lead.
2.Open RH rear and tail doors.
3.Fold RH rear seat forward.
4.Remove 2 fasteners securing front and rear
carpets.
5.Pull back loadspace carpet from fuel pump
access panel.
6.Remove 6 screws securing access panel.
WARNING: Depressurise the system before
disconnecting any components. Fuel
pressure will be present in the system even
if the ignition has been switched off for
some time.
7.Remove access panel.
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
8.Disconnect multiplug and fuel hose from fuel
pump housing.
CAUTION: Always fit plugs to open
connections to prevent contamination.9.Use LRT-19-009 to remove locking ring from
fuel pump housing.
10.Remove fuel pump housing and discard sealing
ring.
Refit
1.Clean fuel pump housing and mating face on
fuel tank.
2.Fit new seal to fuel pump housing.
3.Fit fuel pump housing to fuel tank, fit and tighten
locking ring to 35 Nm (26 lbf.ft) using LRT-19-
009.
4.Connect multiplug and fuel hose to fuel pump
housing.
5.Fit access panel and secure with screws.
6.Position carpet and secure with fasteners.
7.Reposition rear seat.
8.Close rear and tail doors.
9.Connect battery earth lead.
Page 588 of 1007
RESTRAINT SYSTEMS
REPAIRS 75-7
Stalk - rear seat belt - LH - 5 door
$% 76.73.32
Remove
1.Fold rear seat forward.
2.Remove 3 screws from end cover and remove
cover from seat hinge.
3.Remove 4 Torx bolts from seat lock down catch
and remove catch assembly.
4.Remove Torx bolt from seat belt buckle and
remove buckle.Refit
1.Fit buckle to catch assembly and tighten Torx
bolt to 32 Nm (24 lbf.ft).
2.Fit catch assembly to seat and tighten Torx
bolts.
3.Fit catch assembly to seat, fit Torx bolts but do
not tighten at this stage.
4.Fold seat down and check that seat unfolds on
lock down bar correctly. Adjust catch assembly
if required.
5.Tighten catch Torx bolts to 32 Nm (24 lbf.ft).
6.Recheck seat fold.
7.Fit end cover and tighten screws.
8.Reposition rear seats.