horn 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 23 of 1007
CONTENTS
20 CONTENTS
LIGHTING.................................................................................................. 86-2-1
ADJUSTMENTS
Headlamps - pair - align beam - up to 04MY .................................................................................. 86-2-1
Headlamps - pair - align beam - from 04MY ................................................................................... 86-2-1
REPAIRS
Headlamp assembly - up to 04MY.................................................................................................. 86-2-3
Headlamp assembly - from 04MY .................................................................................................. 86-2-4
Lamp assembly - flasher side repeater - front ................................................................................ 86-2-5
Lamp assembly - tail ....................................................................................................................... 86-2-5
Lamp assembly - number plate ...................................................................................................... 86-2-6
Lamp assembly - fog/driving - from 04MY ...................................................................................... 86-2-6
Lamp assembly - rear ..................................................................................................................... 86-2-7
Lamp assembly - centre high mounted stop (CHMSL) ................................................................... 86-2-7
Lamp assembly - glove compartment ............................................................................................. 86-2-8
Lamp assembly - load space .......................................................................................................... 86-2-8
Switch - headlamp levelling ............................................................................................................ 86-2-9
Switch - glove compartment ........................................................................................................... 86-2-9
Switch - hazard warning ................................................................................................................. 86-2-10
Switch - combined direction indicator/headlight/horn ..................................................................... 86-2-10
Switch - rear fog lamp ..................................................................................................................... 86-2-11
CONTROL UNITS ..................................................................................... 86-3-1
REPAIRS
Control unit - window lift ................................................................................................................. 86-3-1
Relay - power folding mirrors - from 02MY ..................................................................................... 86-3-1
Central Control Unit (CCU) ............................................................................................................. 86-3-2
Control Unit - power fold mirrors - up to 02MY ............................................................................... 86-3-3
SECURITY................................................................................................. 86-4-1
REPAIRS
Solenoid/motor - taildoor................................................................................................................. 86-4-1
Switch/push - horn .......................................................................................................................... 86-4-2
Horn ................................................................................................................................................ 86-4-2
Immobilisation - electronic control unit (ECU) - ............................................................................. 86-4-3
Sensor - volumetric - alarm system - 3 door ................................................................................... 86-4-3
Module (ECU) - volumetric - alarm system - 5 door - without sunroof ........................................... 86-4-5
Module (ECU) - volumetric - alarm system - 5 door - with sunroof ................................................ 86-4-7
Receiver - alarm system ................................................................................................................. 86-4-10
Coil - passive immobilisation - alarm system .................................................................................. 86-4-10
Page 151 of 1007
MAINTENANCE
10-4 MAINTENANCE
Seats and Seat Belts
Check
1.Check seat frames are secured to floor and
show no signs of movement.
2.Check operation of seat slide and tilt
mechanisms, ensuring there is no excessive
play between seat cushion and seat back.
3.Check tightness of accessible seat fixings.
4.Fully extract seat belt and allow it to return
under its own recoil mechanism.
5.Check entire length of seat belt webbing for
signs of fraying or damage. Repeat for all belts.
6.Check security of seat belt upper mountings.
7.Check for correct operation of seat belt height
adjusters.
8.Check security of seat belt buckle mountings.
9.Connect each belt to the correct buckle, check
seat belt buckle and tongue are secure.
Release seat belt buckle and check for correct
operation.
10.Check tightness of accessible seat belt
mountings.
Lamps, Horns and Warning Indicators
Check
1.Switch on side, head and tail lights and check
operation.
2.Check headlamp dim/dip operation.
3.Check headlamp levelling operation.
4.Check turn signals and hazard warning lights
operation.
5.Press brake pedal and check operation of
brake lights.
6.Check all exterior lamp lenses for clarity and
condition. Pay particular attention to head lamp
lenses for signs of stone chips or damage.
7.Check horn for loud clear sound.
8.Check operation of all instrument pack warning
and indicator lights.
9.Check for correct operation of interior courtesy
lights.
10.Switch on headlamps (with ignition switch at 'O'
position) and check light reminder warning
operates when door is opened.
Page 512 of 1007
STEERING
REPAIRS 57-19
Refit
1.Position cable, align to heater and steering
column bracket and secure in retaining clips.
2.Align key interlock cable to column lock and
tighten union to 4 Nm (3 lbf.ft).
3.Fit height adjuster clamp bolt and tighten nut to
10 Nm (7.5 lbf.ft). Ensure bolt and plastic stop
are correctly located in slot in column bracket.
4.Fit height adjuster lever and tighten bolt 12 Nm
(9 lbf.ft). Ensure lever is in the fully up position
before tightening bolt. Hold clamp bolt nut to
prevent nut rotation.
5.Connect cable to interlock mechanism.
6.Check key interlock cable adjustment.
+ STEERING, ADJUSTMENTS, Cable
- key interlock - adjust.
7.Fit steering column nacelle.
+ STEERING, REPAIRS, Nacelle -
column.
8.Fit front console.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
9.Connect battery earth lead.
Column assembly - inner & outer
$% 57.41.01
Remove
1.Disconnect battery earth lead.
2.Remove steering column multi purpose switch.
+ LIGHTING, REPAIRS, Switch -
combined direction indicator/headlight/
horn.
3.Disconnect multiplugs from ignition switch and
passive coil.
4.Remove 2 screws securing steering column
aperture trim and remove trim.
Page 515 of 1007
STEERING
57-22 REPAIRS
Refit
1.Remove column from vice.
2.Fit new cable ties to steering column.
3. Models with automatic transmission: Fit key
interlock cable clip.
4.Position steering column to vehicle, locate
steering column on PAS rack, aligning column
coupling with PAS rack input flag.
5.Locate steering column on studs fit nuts but do
not tighten at this stage.
6.Fit bolts and snubber to pivot mountings and
tighten bolts to 14 Nm (10 lbf.ft).
7.Tighten nuts to 14 Nm (10 lbf.ft).
8.Fit and tighten PAS rack pinion clamp bolt to 32
Nm (24 lbf.ft).
CAUTION: Nuts and bolts must be tightened
with weight of vehicle on suspension.
9. Models with automatic transmission:
Remove clamp bolt from height adjuster and
position key interlock cable.
10. Models with automatic transmission: Fit
height adjuster clamp bolt and tighten nut to 10
Nm (7.5 lbf.ft). Ensure bolt and plastic stop are
correctly located in slot in column bracket.
11. Models with automatic transmission: Fit
height adjuster lever and tighten bolt 12 Nm (9
lbf.ft). Ensure lever is in the fully up position
before tightening bolt. Hold clamp bolt nut to
prevent nut rotation.
12. Models with automatic transmission:
Remove starter key from column lock.
13. Models with automatic transmission: Align
key interlock cable to column lock and tighten
union to 4 Nm (3 lbf.ft).
14. Models with automatic
transmission:Position lock to steering column
assembly and fit shear bolts. Do not tighten
shear bolts at this stage.
15. Models with automatic transmission: Insert
starter key, check operation of steering lock
and that key turns freely.
16. Models with automatic transmission:
Ensure correct operation of key interlock cable.
17. Models with automatic transmission:
Remove starter key from column lock.
18. Models with automatic transmission:
Tighten shear bolts fully and shear heads off.
19. Models with automatic transmission: Fit
passive coil.
20. Models with automatic transmission:
Position ignition switch to column, fit and
tighten screws.
21. Models with automatic transmission:
Secure key interlock cable in clip.
22. Models with automatic transmission:
Ensure key interlock cable is correctly fitted.23.Fit side support bolt and tighten to 10 Nm (7.5
lbf.ft).
24.Position harness and secure cable ties.
25.Fit fusebox cover and close glove box lid.
26.Connect multiplugs to column switch and
passive coil.
27.Fit aperture trim and secure with screws.
28. Fit steering column multi purpose switch.
+ LIGHTING, REPAIRS, Switch -
combined direction indicator/headlight/
horn.
29.Connect battery earth lead.
Page 519 of 1007
STEERING
57-26 REPAIRS
10.Using a broad round edged tool, carefully prise
horn switches from steering wheel.
11.Noting fitted position, disconnect 2 Lucars and
remove horn switch.
12.Repeat for other horn switch.
13. Disconnect multiplugs from cruise control (if
fitted) and radio control switches.
14.Release harness from clips and remove
harness.
15. Models with cruise control: Remove 2
screws securing cruise control switches to
steering wheel.
16. Models with cruise control: Remove cruise
control switches from steering wheel.
17.Remove 2 screws securing radio switches to
steering wheel.
18.Remove radio switches from steering wheel.Refit
1.Fit radio switches to steering wheel and secure
with screws.
2. Models with cruise control: Fit cruise control
switches to steering wheel and secure with
screws.
3.Position harness to horn, cruise control (if
fitted) and radio switches and secure in clips.
4.Position horn switch and connect Lucars.
5.Repeat for other horn switch.
6.Connect multiplugs to cruise control and radio
control switches.
7. Td4 models: Position damper, fit and tighten
screws.
8.Remove tape from rotary coupler.
9.Ensure road wheels are in straight ahead
position and indicator cancelling cam is aligned
horizontally.
10.Fit steering wheel to column and ensure
spokes are horizontal.
11.Fit new self locking nut and tighten to 45 Nm
(33 lbf.ft).
12.Connect multiplug to rotary coupler.
13.Fit drivers airbag.
+ RESTRAINT SYSTEMS, REPAIRS,
Air bag - steering wheel.
Page 780 of 1007
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.
Page 781 of 1007
PANEL REPAIRS
77-2-26 REPAIRS
Refit
1.Fit bonnet stay.
2.Fit bonnet lock.
3.Fit windscreen washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
4.Fit horn.
+ SECURITY, REPAIRS, Horn.
5.Fit air intake hose.
6.Fit battery. Do not connect earth lead.
+ CHARGING AND STARTING,
REPAIRS, Battery.
7.Fit bumper valance LH and RH attachment
brackets.
8.Fit LH and RH engine bay shields.
9.Fit LH and RH headlamps.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY. Secure headlamps
wiring.
10.Fit PAS fluid cooler.
+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
11.Fit radiator.
+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
12.Fit front bumper armature.
13.Fit front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
14.Connect all ECUs.
15.Connect alternator.
16.Connect battery earth lead.
Page 782 of 1007
PANEL REPAIRS
REPAIRS 77-2-27
Bonnet locking platform
In this procedure the bonnet locking platform
reinforcement is also replaced in conjunction with the
bonnet locking platform.
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 radiator.
+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
6.Remove both headlamp assemblies.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
7.Remove horn.
+ SECURITY, REPAIRS, Horn.
8.Remove battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
9.Remove air intake hose.
10.Remove bonnet lock.
11.Support bonnet in open position.
12.Remove bonnet stay.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Refit
1.Fit bonnet stay.
2.Fit bonnet lock.
3.Fit air intake hose.
4.Fit battery. Do not connect earth lead.
+ CHARGING AND STARTING,
REPAIRS, Battery.
5.Fit horn.
+ SECURITY, REPAIRS, Horn.
6.Fit both headlamp assemblies.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
7.Fit radiator.
+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
8.Fit front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
9.Connect all ECUs.
10.Connect alternator.
11.Connect battery earth lead.
Page 783 of 1007
PANEL REPAIRS
77-2-28 REPAIRS
Headlamp mounting panel
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 headlamp assembly.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
8.Release wiring to headlamp and position aside.
9. LH side: Remove front bumper LH support
bracket.
10. LH side: Remove battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
11. LH side: Remove horn.
+ SECURITY, REPAIRS, Horn.
12. LH side: Remove air intake hose.
13. RH side: Remove front bumper RH support
bracket.
14. RH side: Remove windscreen washer
reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
15. 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.
Refit
1. LH side: Fit air intake hose.
2. LH side: Fit horn.
3. LH side: Fit battery. Do not connect earth lead.
+ CHARGING AND STARTING,
REPAIRS, Battery.
4. LH side: Fit front bumper LH support bracket.
5. RH side: Fit PAS fluid cooler.
+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
6. RH side: Fit windscreen washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
7. RH side: Fit front bumper LH support bracket.
8.Fit headlamp assembly.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.Secure headlamp
wiring.
9.Fit radiator.
+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
10.Fit front bumper armature.
11.Fit front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
12.Connect all ECUs.
13.Connect alternator.
14.Connect battery earth lead.