Blown-Air Cooling Heat Exchanger: Td4 Engine Vehicles (Freelander 1)

Dismantling

1. Disconnect the negative battery terminal.

2. Remove the front bumper.

EXTERIOR PARTS, REPAIR WORK, Front bumper assembly - for cars up to model year 2004.

3. Disconnect the combined fan and thermostat connector from the harness.



4. Remove the connector from the bracket.

5. Loosen the connector bracket mounting nut and move the bracket to the side.

6. Place a container under the transmission heat exchanger hoses to collect the fluid.



7. Disconnect the quick-release hose connectors from the heat exchanger.

CAUTION: Before disconnecting or removing system components, make sure that the adjacent surfaces of the joints are free of dirt. Install plugs in the openings of the fittings and pipes to prevent dirt from entering the system.

8. Unscrew the 3 bolts securing the blown heat exchanger to the chassis and move it to the side.



9. Unscrew the 2 screws, release the air duct from the clamps and move it to the side.



10. Unscrew the 5 bolts securing the fan casing to the heat exchanger and move the casing to the side.





11. Unscrew the 4 nuts securing the fan motor to the casing and remove it.

NOTE: If disassembly was performed only to provide access to other system components, no further disassembly operations should be performed.

12. Unscrew the nuts securing the hoses to the heat exchanger fittings and move the hoses to the side.

CAUTION: To avoid damaging components, loosen and tighten nuts while holding the fitting with a second wrench.

13. Remove and discard the sealing ring.

Installation

1. Install new O-rings on the heat exchanger hoses.

2. Connect the hoses to the heat exchanger, tighten the nuts and tighten them to a torque of 25 Nm.

3. Install the fan casing onto the heat exchanger, screw in the bolts and tighten them to 5 Nm.



4. Install the fan motor assembly onto the casing, screw in the bolts and tighten them to 5 Nm.

5. Install the air duct and secure it with screws.

6. Install the blown heat exchanger assembly, screw in the bolts and tighten the upper bolt to 5 Nm. The lower bolts should be tightened to 10 Nm.

7. Make sure the surface of the fittings is clean, connect the flexible hoses to them and secure.

8. Install the connector bracket and tighten the nut to 10 Nm.

9. Connect the connector to the harness, secure the connector in the bracket.

10. Reinstall the front bumper.

EXTERIOR PARTS, REPAIR WORK, Front bumper assembly - for cars up to model year 2004.

11. Connect the negative battery terminal.