Engine and manual 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 glow plug control unit.

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

10. Disconnect the engine control system harness clamps.

11. Disconnect the engine harness from the mounting box and place it on top of the engine.



12. Using the LRT-37-051 tool, disconnect and remove the clutch drive pipe.





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



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



15. Disconnect the connector from the reversing light switch.



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





17. 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.

18. Prepare containers to collect fuel residues.



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



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





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



22. Loosen the clamps and disconnect the hoses from the heater.



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



24. Place a container under the power steering reservoir, loosen the clamp and remove the hose from the reservoir. Let the working fluid drain.

CAUTION: Avoid spilling oil or liquid on the generator.

25. Cover the generator to prevent it from being exposed to working fluid.



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



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



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



29. Remove the rear cross member.

FRONT SUSPENSION, REPAIR WORK, Front subframe.

30. 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.

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

32. Remove the exhaust pipe.

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

33. Using the LRT-37-050 tool, disconnect the gear selector rod from the gear selector shaft.

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



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



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

37. 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.

38. Remove the two bolts that secure the gear shift rods to the front shield and secure the rods to the side.

39. Drain the oil from the gearbox.

MECHANICAL GEARBOX - GETRAG, ADJUSTMENT, Replacing transmission oil in the box.

40. Drain the oil from the transfer case.

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

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



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



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



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

49. Lower the engine and gearbox to the floor.

Make sure that the turbocharger hose does not get caught on the shift rods located on the front shield.

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

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 hydraulic support.

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

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

7. Install the exhaust pipe.

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

8. Place the gear shift rods on the front shield, screw in the mounting bolts and tighten them to a torque of 25 Nm.

9. Attach the upper and lower links to the gear selector lever.

10. 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.

11. Install the rear beam in place.

FRONT SUSPENSION, REPAIR WORK, Front subframe.

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

13. 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.

14. Models with air conditioning: Install the compressor in place and tighten the mounting bolts. Tightening torque 25 Nm.

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

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

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

18. Models with air conditioning: Install the belt on the compressor pulley.

19. 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.

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

21. Wipe the vacuum receiver hoses and fittings.

22. Connect the vacuum hoses to the vacuum receiver.

23. Wipe the vacuum pump hoses and fittings.

24. Connect the vacuum hoses and tighten the clamps.

25. Wipe the hoses and fittings of the power steering reservoir.

26. Place the hoses on the power steering reservoir fittings and tighten the clamps.

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

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

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

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

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

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

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

34. Connect the connector to the first gear engagement contact sensor.

35. Connect the reversing light switch connector.

36. Connect the clutch pipe quick release connector.

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

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

39. Secure the wire harnesses with clamps and screws.

40. Connect the connectors.

41. Install the engine control module (ECM).

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

42. Fill the gearbox with oil.

MECHANICAL GEARBOX - GETRAG, ADJUSTMENT, Replacing transmission oil in the box.

43. Untie the hood and close it.

44. Reinstall the battery tray.

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

45. Install the inlet hoses.

46. Fill the engine with coolant.

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