Engine and automatic transmission (Freelander 1)

Dismantling

1. Place the vehicle on a two-post lift.

2. Disconnect the negative battery terminal.

3. Secure the hood in a vertical position.

4. Drain the coolant from the engine.

COOLING SYSTEM: Td4 engine, ADJUSTMENTS, Draining coolant, flushing the system and filling.

5. Remove the air intake hoses.

6. Remove the battery tray.

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

7. Remove the Engine Control Module (ECM).

ENGINE MANAGEMENT SYSTEM: EDC, REPAIR WORK, Engine Control Unit (ECM).

8. Disconnect the connector from the automatic transmission control unit.

9. Disconnect the connector from the glow plug control unit.

10. Disconnect the engine control harness multi-position connector from the junction box.

11. Loosen the four screws and remove the wiring harness clamps.

12. Disconnect the engine harnesses from the mounting box and place them on top of the engine.



13. Remove the bolt and disconnect the ground bus from the gearbox.





14. Unclip the two transmission wiring harness connectors and disconnect them.



15. Loosen the nut securing the selector cable to the gearbox lever.

16. Remove the clip, disconnect the selector cable and remove the lever.



17. Remove the cap from the pole piece and disconnect the two wires from the starter solenoid relay.





18. Loosen the clamp and disconnect the air hose leading to the air intercooler from the engine.

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.

19. Prepare containers to collect fuel residues.



20. Loosen the clamps and disconnect the fuel hoses from the fuel rail.



21. Loosen the clamp and disconnect the upper hose from the radiator.





22. Loosen the clamp and disconnect the hose from the cooling system distribution pipe.



23. Loosen the 2 clamps and disconnect the hoses from the heater.

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



25. Loosen the two clamps and disconnect the cooling system hoses from the transmission heat exchanger.





26. Unscrew the bolt securing the power steering tube clamp to the eye.



27. Loosen the clamp and disconnect the vacuum hose from the vacuum pump.



28. Mark the location of the vacuum tubes and remove both vacuum tubes from the reservoir.



29. Loosen the clamps and remove the inlet and outlet hoses from the torch bed heater (FBH).



30. Remove the rear cross member.

FRONT SUSPENSION, REPAIR WORK, Front subframe.

31. Drain the oil from the gearbox.

AUTOMATIC TRANSMISSION: JATCO, ADJUSTMENTS, Replacement of working fluid in the box.

32. Drain the oil from the transfer case.

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

33. 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.

34. With the help of a partner, move the hubs outward and remove the drive shafts from the transfer case and from the gearbox.

35. Remove the exhaust pipe.

COLLECTORS AND EXHAUST SYSTEM - Td4, REPAIR WORK, Intake pipe.

36. Raise one rear wheel so that you can rotate the driveshaft to gain access to the bolts.



37. To simplify subsequent assembly, mark the position of the viscous coupling in relation to the transfer case flange.



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

Remove the drive 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.

40. Models with air conditioning system: Loosen the axle and bolt securing the air conditioning compressor belt tensioner.

41. Models with air conditioning: Remove the belt from the compressor pulley.



42. Models with air conditioning: Loosen the bolt securing the compressor bracket to the pan, but do not remove it.



43. Models with air conditioning: Disconnect the connector from the compressor.



44. Models with air conditioning: Remove the three bolts securing the distribution pipe to the sump and to the cylinder block.



45. Models with air conditioning: Remove the 3 bolts securing the air conditioning compressor to the bracket, move the compressor to the side and secure it.



46. Install the LRT-12-138 crossbar onto the rigging chains and hook them onto the engine lifting eyes.

47. Remove the hydraulic support.

ENGINE - Td4, Inlet and outlet camshafts, Right engine hydraulic support.

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



49. Install the LRT-12-163 onto the accessory drive belt tensioner pulley nut. Turn the tensioner pulley counterclockwise to release the belt tension and remove the belt.



50. Unscrew the bolts and remove the power steering pump pulley.



The article was copied from the website LRman.ru

51. Unscrew the 4 bolts securing the power steering pump, move the pump away and secure it.



52. Unscrew the through bolt securing the left engine support to the gearbox.

53. With the help of a partner, avoiding obstacles, lower the engine with the gearbox to the floor.



54. Remove the silent block from the support.

Installation

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

2. Install the silent blocks on the support.

3. Raise the engine with the gearbox, move the gearbox bracket to the installation location.

4. Insert the through bolt of the gearbox bracket into the support on the body and tighten the bolt to a torque of 100 Nm.

5. Install the power steering pump. Tighten the M8 screws to 24 Nm and the M6 screws to 10 Nm.

6. Install the power steering pump pulley and align the bolt holes with the threaded sockets. Make sure that the "FRONT" mark faces outward. Tighten the bolts with finger force.

7. Use the LRT-12-163 tool to move the tensioner pulley away and, with the help of a partner, put the belt on. Check that the belt is correctly positioned in the pulley grooves.

8. Tighten the pump drive pulley bolts to 10 Nm.

9. Install the hydraulic support.

ENGINE - Td4, Inlet and outlet camshafts, Right engine hydraulic support.

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

11. Install the exhaust pipe.

COLLECTORS AND EXHAUST SYSTEM - Td4, REPAIR WORK, Intake pipe.

12. Install the cardan shaft on the drive flange of the transfer case so that the previously applied marks are aligned. Tighten the nuts and bolts to a torque of 40 Nm.

13. Install the rear beam in place.

FRONT SUSPENSION, REPAIR WORK, Front subframe.

14. Wipe the ends of the drive shaft and the places where it is installed in the hub and in the differential.

15. With the help of a partner, insert the shafts into the gearbox, holding them at the correct angle so as not to damage the gearbox seals.

16. Models with air conditioning: Install the compressor, screw in the bolts and tighten them to a torque of 25 Nm.

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

18. Models with air conditioning: Install the compressor bracket on the tray, screw in the bolts and tighten them to a torque of 10 Nm.

19. Models with air conditioning: Install the lower coolant pipe on the pan, screw in the bolts and tighten them. Tightening torque 10 Nm.

20. Models with air conditioning: Check that the compressor drive belt, compressor pulley, crankshaft pulley and rollers are clean.

21. Models with air conditioning: Install the belt onto the compressor pulley.

22. Models with air conditioning: Tighten the compressor drive belt.

AIR CONDITIONING SYSTEM, Air conditioning compressor drive belt - for models with Td4 engine, Air conditioning compressor drive belt - for models with Td4 engine.

23. Connect the cooling system hoses to the torch heater and secure them with clamps.

24. Wipe the vacuum receiver hoses and fittings.

25. Connect the vacuum hoses to the vacuum receiver.

26. Wipe the vacuum pump hoses and fittings.

27. Connect the vacuum hoses and tighten the clamps.

28. Tighten the power steering tube mounting bolt to the eye to a torque of 10 Nm.

29. Connect the heater hoses and secure them with a clamp.

30. Connect and secure the cooling system hoses to the transmission heat exchanger.

31. Connect the cooling system hose to the distribution pipe and secure it with a clamp.

32. Connect the upper hose to the radiator and secure with a clamp.

33. Connect the fuel lines to the clamps on the fuel rail.

34. Place the hose onto the air-to-air intercooler radiator and secure it with a clamp.

35. Attach the multi-position connectors to the transmission and secure the connectors to the clips on the support.

36. Install the selector lever, connect the selector cable and secure the cable housing to the bracket.

37. Adjust the selector cable.

AUTOMATIC TRANSMISSION: JATCO, ADJUSTMENTS, Selector cable adjustment.

38. Connect the battery cable to the starter solenoid relay and tighten the nut to 13 Nm.

39. Place the ground wire on the gearbox and tighten the mounting bolt. Tightening torque 25 Nm.

40. Route the wiring harnesses to the junction box and install the bushings.

41. Secure the wire harnesses with clamps and screws.

42. Connect the connectors.

43. Connect the 3 multi-position connectors to the automatic transmission control unit.

44. Install the engine control module (ECM).

ENGINE MANAGEMENT SYSTEM: EDC, REPAIR WORK, Engine Control Unit (ECM).

45. Fill the automatic transmission with working fluid.

AUTOMATIC TRANSMISSION: JATCO, ADJUSTMENTS, Replacement of working fluid in the box.

46. 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.

47. Reinstall the battery tray.

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

48. Install the inlet hoses.

49. Fill the engine with coolant.

COOLING SYSTEM: Td4 engine, ADJUSTMENTS, Draining coolant, flushing the system and filling.

50. Untie the hood and close it.

51. Connect the negative battery terminal.