Engine and gearbox (Freelander 1)

Dismantling

1. Disconnect the negative battery terminal.

2. Remove the hood.

EXTERIOR PARTS, REPAIR WORK, Hood.

3. Drain the coolant from the engine.

COOLING SYSTEM: MODIFICATION K, volume 1.8, ADJUSTMENTS, Draining the coolant, flushing the system and filling.

4. Drain the oil from the gearbox.

MECHANICAL GEARBOX - PG1, ADJUSTMENTS, Replacing transmission oil in the box.

5. Drain the oil from the transfer case.

TRANSFER CASE, ADJUSTMENTS, Changing the transmission oil in the transfer case: except for North American market countries.

6. If necessary, drain the oil from the engine.

MAINTENANCE, Engine oil and oil filter - K1.8.

7. Unscrew the 6 bolts securing the right and left mudguard panels and remove the panels.



8. Loosen the nuts securing the rear of the lower suspension arm.



9. Unscrew the 2 bolts securing the lower suspension arm bushing cage.

10. Unscrew the bolts of the lower arm axle bushings.

11. Disconnect the lower arm from the beam.



12. Install the LRT-54-026 tool onto the inner joint of the drive shaft. Using a lever, release the drive shafts from the transfer case and gearbox.



13. Remove and discard the drive shaft retaining rings.



14. Unscrew the 2 nuts securing the inlet pipe to the exhaust manifold, move the inlet pipe away and dispose of the gasket.





15. To facilitate subsequent assembly, apply position marks to the front propeller shaft.

16. Unscrew 6 nuts and remove the bolts securing the propeller shaft to the drive flange of the transfer case.

17. Remove the propeller shaft from the transfer case drive flange and tie it to the side.

CAUTION: When removing the three-roller joint from the transfer case, care must be taken. To avoid damaging the boot, it must not be completely stretched, and the joint housing must be protected from impacts.

18. Remove the gearshift rod pivot pin cover, remove and discard the pin.

19. Disconnect the gear shift rod from the gear selector rod.

20. Loosen the bolt securing the gearshift rod spacer to the transfer case bracket and remove the spacer from the bracket.





21. Unscrew the bolt securing the lower cross member to the bracket on the pallet.

22. Loosen the bolt securing the lower engine crossmember to the rear beam, move the crossmember away from the bracket on the pallet.



23. Disconnect the reversing light switch connector.

24. Disconnect the connector from the first gear engagement contact sensor.

25. Disconnect the clamp securing the first gear contact sensor harness to the clutch slave cylinder bracket.

26. Unscrew the 3 bolts securing the slave cylinder bracket to the gearbox and secure the bracket to the side.



27. Models with air conditioning: Using a 13 mm wrench, turn the accessory drive belt tensioner by the hexagon clockwise until it stops to loosen the belt tension.



28. Models with air conditioning: While holding the tensioner in this position, insert a pin, up to 3 mm in diameter, through the center of the hexagon into the rear plate of the tensioner. Remove the belt from the compressor pulley.



29. Models with air conditioning: Disconnect the connector from the cooling system compressor.

30. Models with air conditioning system: Unscrew the 3 bolts securing the air conditioning system compressor to the common (with the generator) bracket, remove the compressor from the bracket and secure it to the side.

31. Lower the car lift.

32. Remove the air cleaning filter.

FUEL SUPPLY SYSTEM OF GASOLINE ENGINE, ADJUSTMENTS, Air cleaning filter, engine K1.8.

33. Remove the battery tray.

ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Support tray - battery.

34. Remove the Engine Control Module (ECM).

ENGINE MANAGEMENT SYSTEM: MEMS, REPAIR WORK, Engine Control Unit (ECM): unit that implements ignition and fuel supply strategies.

35. Disconnect the wiring harness connector from the junction box.



36. Remove the air hose and rubber boot for the harness routing from the mounting box.

37. Unfasten the 4 latches securing the platform to the mounting box, remove the platform and place it aside.



38. Loosen the nut, release the retainer and remove the mounting box.

39. Remove the fuse box cover in the engine compartment.



40. Unscrew the 2 bolts securing the battery and starter buses to the fuse box.

41. Disconnect the connector from the fuse box.



42. Disconnect the clamp securing the battery busbar to the mounting box bracket.



43. Disconnect the 2 clamps securing the starter bus to the mounting box bracket.



44. Loosen the nut securing the ground busbar to the body and remove the busbar from the stud.



45. Disconnect the connector from the purge solenoid valve.

46. Place a rag near the fuel supply hose to prevent spilled fuel from spreading.

CAUTION: Fuel leakage is inevitable during this operation. Take safety measures to prevent fire or explosion.

47. Disconnect the fuel supply hose from the fuel rail.

CAUTION: Always plug the fittings and holes to protect the system from dirt.

48. Loosen the clamp and disconnect the purge hose from the intake manifold.

49. Unscrew the throttle control cable adjusting nut from the bracket.

50. Remove the cable from the throttle control sector.

51. Press the plastic shoulders of the connector and disconnect the brake booster hose from the intake manifold.



52. Loosen the clamps and remove the heater inlet and outlet hoses.



53. Loosen the clamp and disconnect the upper hose from the elbow pipe of the cooling system.



54. Loosen the clamp and disconnect the expansion tank hose from the intake manifold.



55. Loosen the clamp and disconnect the hose from the bottom of the expansion tank.

56. Disconnect the expansion tank from the mount on the body.



57. Unscrew the 2 bolts securing the oil seal cover to the cylinder head and remove the cover.

58. Install the LRT-12-135/1 lifting eye in place of the camshaft oil seal cover, screw in and tighten the bolts.



59. Install the LRT-12-135/2 lifting eye onto the front of the cylinder head and secure it with bolts.



60. Attach the LRT-12-138 adjustable beam hoist to the engine.



61. Unscrew the bolt securing the crossmember to the left engine support.

62. Unscrew the through bolt securing the left engine support to the bracket.

63. Unscrew the four bolts securing the left support bracket to the body.

64. Loosen the through bolt securing the left engine support to the bracket and remove the bracket.



65. Remove the power steering reservoir from the bracket and secure it to the side.



66. Remove the bolt securing the upper right engine crossmember to the upper bracket on the engine.

67. Loosen the bolt securing the upper right engine crossmember to the body and move the crossmember away from the upper bracket.

68. Unscrew the nut securing the upper bracket to the right hydraulic support, unscrew the two bolts securing the upper bracket to the engine and remove the upper bracket.

69. Raise the engine and gearbox enough to provide access to the power steering pump.



70. Loosen the three power steering pump pulley mounting bolts.

71. Using a 13 mm spanner, turn the power steering pump belt tensioner and insert a 4 mm pin through the center of the hexagon into the rear plate of the tensioner. Remove the power steering pump belt.

72. Unscrew the 3 bolts securing the power steering pump pulley and remove the pulley.



73. Unscrew the 5 bolts securing the power steering pump, move the pump away and secure it.

74. With the help of a partner, avoiding obstacles, lift the engine with the gearbox from the engine compartment.

Installation

1. Attach the LRT-12-138 adjustable beam hoist to the engine.

2. With the help of a partner, lower the engine and gearbox into the engine compartment far enough to allow the power steering pump to be installed.

3. Install the power steering pump on the bracket, screw in the bolts and tighten them to a torque of 25 Nm.

4. Install the pulley on the power steering pump, screw in the bolts and tighten them to a torque of 10 Nm.

5. Place the belt on the power steering pulley, move the tensioner away, remove the pin and release the tensioner.

6. Lower the engine and gearbox to the mounting points.

7. Install the bracket onto the left engine mount, insert the through bolt but do not tighten at this stage.

8. Install the left engine bracket on the body, screw in the bolts and tighten them to a torque of 45 Nm.

9. Tighten the left engine mount through bolt to 80 Nm.

10. Adjust the engine position to fit the top bracket.

11. Install the upper bracket on the right hydraulic support and on the engine, screw in the bolts and tighten them to a torque of 170 Nm, fit the nuts and tighten them to a torque of 85 Nm.

12. Lower the chains, unhook and remove the LRT-12-138 crossbar.

13. Install the upper right cross member onto the upper bracket, screw in the bolt and tighten it to 80 Nm.

14. Tighten the upper cross member mounting bolt to the body to a torque of 80 Nm.

15. Secure the power steering reservoir to the bracket.

16. Loosen the bolt securing the LRT-12-135/2 lifting eye to the front of the cylinder head and remove the eye.

17. Unscrew the 2 bolts securing the LRT-12-135/2 lifting eye to the rear of the cylinder head and remove the eye.

18. Wipe the camshaft oil seal cover and the mating surface.

19. Install the oil seal cover, screw in the bolts and tighten them to a torque of 25 Nm.

20. Attach the hose to the bottom of the expansion tank and secure it with a clamp. Secure the hose to the clamp on the body.

21. Connect the expansion tank hose to the intake manifold and secure it with a clamp.

22. Connect the upper hose to the elbow and secure with a clamp.

23. Connect the heater inlet and outlet hoses and secure them with a clamp.

24. Connect the brake booster hose to the intake manifold.

25. Secure the throttle control cable to the throttle sector and the cable casing to the bracket.

26. Connect the fuel supply hose to the fuel rail.

27. Connect the connector to the purge solenoid valve of the adsorber.

28. Place the ground wire on the stud, screw on the nut and tighten it. Tightening torque 9 Nm.

29. Place the battery busbar on the mounting box bracket and secure the busbar with a clamp.

30. Connect the battery and starter buses to the fuse box in the engine compartment, screw in the bolts and tighten them to 8 Nm.

31. Secure the 2 starter bar clamps to the mounting box bracket.

32. Connect the connector to the fuse box.

33. Replace the fuse box cover in the engine compartment.

34. Install the mounting box, secure it with the clamp, tighten the nut and tighten it to a torque of 9 Nm.

35. Install the platform into the mounting box and secure it with fasteners.

36. Attach the air hose and rubber boot for the harness routing to the junction box and secure them.

37. Connect the wiring harness to the junction box.

38. Install the engine control module (ECM).

ENGINE MANAGEMENT SYSTEM: MEMS, REPAIR WORK, Engine Control Unit (ECM): unit that implements ignition and fuel supply strategies.

39. Raise the car on a lift.

40. Models with air conditioning: Install the air conditioning compressor on the bracket, screw in the bolts and tighten them to 25 Nm.

41. Models with air conditioning: Connect the electrical connector to the air conditioning compressor.

42. Models with air conditioning: Move the belt tensioner away, remove the pin, place the belt on the compressor pulley and release the tensioner.

43. Install the clutch slave cylinder mounting bracket on the gearbox, screw in the bolts and tighten them to a torque of 25 Nm.

44. Connect the connector to the first gear contact sensor and secure the harness with a clamp to the slave cylinder bracket.

45. Connect the reversing light switch connector.

46. Install the lower cross member onto the tray bracket, screw in the bolts and tighten them to a torque of 80 Nm.

47. Tighten the lower cross member to rear beam mounting bolt to a torque of 80 Nm.

48. Install the gear shift rod spacer, screw in the bolt and tighten it to 25 Nm.

49. Install the shift rod onto the selector rod, install the NEW pivot pin and replace the cover.

50. Install the cardan shaft on the transfer case drive flange so that the previously applied marks are aligned. Tighten the nuts and bolts to a torque of 42 Nm.

51. Place a new gasket on the exhaust manifold flange, install the inlet pipe and tighten the nuts to 75 Nm.

52. Wipe the splined portion of the drive shaft and the mating splines in the gearbox.

53. Insert the drive shafts into the transfer case and into the gearbox, checking that the retaining rings of each shaft enter their sockets.

54. Insert the lower arm bushings, screw in but do not tighten the bolts.

CAUTION: Nuts and bolts must be tightened when the weight of the vehicle is supported by the suspension.

55. Clean the slot in the subframe under the rubber bushing and the mating surfaces.

56. Align the bushing sockets so that the cylindrical pin is correctly positioned. Screw in the bolts and tighten them to a torque of 105 Nm.

57. Install the left and right mudguard panels, screw in and tighten the mounting bolts.

58. Lower the car.

59. Tighten the lower arm front bushing mounting bolts. Tightening torque 175 Nm.

60. Tighten the lower arm rear bushing mounting bolts. Tightening torque 140 Nm.

61. Reinstall the battery tray.

ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Support tray - battery.

62. Adjust the throttle control cable.

FUEL SUPPLY SYSTEM OF GASOLINE ENGINE, ADJUSTMENTS, Throttle control cable - checking and adjustment: engine K1.8.

63. Install the air cleaner.

FUEL SUPPLY SYSTEM OF GASOLINE ENGINE, ADJUSTMENTS, Air cleaning filter, engine K1.8.

64. Add oil to the engine if necessary.

MAINTENANCE, Engine oil and oil filter - K1.8.

65. Fill the transfer case with oil to the required level.

TRANSFER CASE, ADJUSTMENTS, Changing the transmission oil in the transfer case: except for North American market countries.

66. Fill the gearbox with oil.

MECHANICAL GEARBOX - PG1, ADJUSTMENTS, Replacing transmission oil in the box.

67. Add coolant to the cooling system.

COOLING SYSTEM: MODIFICATION K, volume 1.8, ADJUSTMENTS, Draining the coolant, flushing the system and filling.

68. Connect the negative battery terminal.

69. Install the hood.

EXTERIOR PARTS, REPAIR WORK, Hood.