Steering System Land Rover Freelander L314

GENERAL

The major steering components comprise a shock absorbing telescopic steering column, a Power Assisted Steering (PAS) rack, a PAS pump, a fluid reservoir, a fluid cooler and fluid pipes and hoses. (Scheme 1)

Scheme 1

STEERING COLUMN

The steering column design incorporates an energy absorbing mechanism to reduce driver impact loads in the event of a collision. The column is mounted on four captive studs which are located in an extension to the bulkhead. The two lower mountings are fixed and cannot move when loads are applied to them. The upper mounting is designed to disengage or deform when a load is applied, allowing the column to collapse in the event of an accident. The steering column is adjustable to allow the steering wheel to be moved vertically up or down to the desired position. The steering column is not serviceable and must be replaced as a complete assembly if necessary. (Scheme 2)

Scheme 2

The upper column tube is telescopic and can slide over the lower column tube. The upper column tube provides for the location of the steering lock and ignition switch and also the steering switch gear and a rotary coupler. The rotary coupler provides the electrical connection for the steering wheel mounted airbag and the switches for the horn and, where fitted, In-Car Entertainment (ICE) and cruise control.

The central shaft comprises of two parts and is located in bearings in the upper and lower column tubes. The upper shaft is located inside the lower shaft. Mating cross holes in each shaft are connected by nylon injection molded shear pins.

The upper shaft is splined to accept the steering wheel. The lower shaft is connected by a universal joint to the intermediate shaft. A second universal joint on the opposite end of the intermediate shaft is attached to a split adaptor. The adaptor is splined and mates with the splined input shaft from the steering rack.

The upper mounting bracket has two open slots with a Polytetrafluorethylene (PTFE) coated, metal "U" clip over each slot. Two soft metal CURLING plates are riveted to the mounting bracket and cover the slots.

The mounting studs pass through the "U" clips and the curling plates. The lock nuts that retain the upper mountings to the bulkhead extension are tightened to between 12-15 Nm (9-11 ft. lbs). This torque figure controls the breakout load required to move the upper mounting brackets from the studs in the bulkhead extension and is critical to the crash performance of the column.

Energy absorption is achieved by the following mechanism: When an axial load is applied to the steering column, the mounting bracket deforms or slides out of the "U" clips and the curling plates deform. The "U" clips remain captive on the studs When the column mounting moves, the upper column tube slides on the lower column tube and allows approximately 63 mm (2.5 in) maximum of axial movement. The nylon shear pins holding the upper and lower shafts together shear, allowing the central shaft to telescope the same amount as the column tubes.

In the event of a collision where the steering rack itself moves, the two universal joints in the column allow the intermediate shaft to articulate, minimizing movement of the column towards the driver. If movement continues after articulation of the intermediate shaft, the nylon shear pins retaining the two halves of the central shaft shear causing the shafts to 'telescope' together reducing further column intrusion.

The steering wheel comprises a cast center and wire frame onto which the soft polyurethane foam is molded. A horn switch is located at each side of the wheel. On models with a high specification ICE system and/or cruise control, additional switches are located on the steering wheel for control of one or both features. All switches are connected by wires to the rotary coupler connector.

Protection for the drivers face and upper torso is provided by an SRS airbag located in the center of the steering wheel under a plastic cover.

The column adjuster is located on the left hand side of the steering column and allows the steering column and wheel to be tilted up or down over a range of approximately 3.5° or 30 mm (1.2 in) of vertical movement of the steering wheel. The column adjuster comprises a bolt which passes through each side of the column upper mounting bracket. The column adjustment lever is attached to a two-start left hand threaded nut which screws onto the bolt.

When the lever is lowered the nut is slackened and allows the column to be moved up or down to the desired position. Lifting the lever upwards tightens the nut, clamping the mounting bracket to the column, retaining the steering column in the selected position. The nut tightening torque is 10.5 Nm (7.7 ft. lbs) which gives the correct FEEL to the lever operation.

The steering lock houses the ignition switch, ignition illumination light ring, key lock barrel and the security system transponder coil.

The steering lock is attached to the upper column with a clamp plate and two shear bolts. The bolts are tightened to a torque which shears off the heads of the bolts preventing easy removal of the steering lock.

The steering lock operates by a bolt, which emerges when the ignition key is turned to position 0 and the ignition key removed. The bolt engages in a lock collar located on the upper shaft in the upper column tube. The lock collar is attached to the upper shaft by a WAVE FORM interference ring, which allows the lock collar to slip on the upper shaft if a torque of 200 Nm (147.5 ft. lbs) or higher is applied. This prevents the bolt being sheared, by someone forcibly turning the steering wheel while the steering lock is engaged, yet still effectively locks the steering. The steering lock is also designed to be resistant to slide hammer and shock retraction.

STEERING RACK

The steering rack is unique in having the track rods mounted at a central location on the rack. The track rods are very long and combined with the optimized steering geometry provide low levels of BUMP STEER. (Scheme 3)

Scheme 3

The steering rack is mounted in the engine compartment on the lower part of the bulkhead. The rack is retained with two bolts through cast lugs near the valve unit and two bolts which secure a clamp over the opposite end of the rack. The lower bolt through the cast lug is fitted with a large washer. The steering rack is handed for left and right hand drive vehicles.

The rack requires 3.2 turns from lock to lock and the rack and pinion has an overall ratio of 19.6:1.

A valve unit is fitted to one end of the steering rack and connects, via a splined input shaft, to the adaptor of the steering column. The valve unit has four hydraulic connections; a pressure feed from the PAS pump, a return line to the reservoir and two pressure lines to the annulus and full area of the hydraulic cylinder.

An input shaft, installed through the valve unit, is connected to a pinion gear which drives on a rack which, in turn is connected to the piston rod in the hydraulic cylinder.

At a central position on the rack are two threaded holes which allow for the attachment of the track rods. Rubber bellows cover the movement area of the rack.

Two hydraulic ports, one at each end of the hydraulic cylinder of the rack, are connected by metal pipes to the valve unit. The ports supply hydraulic pressure to the annulus and full area of the cylinder. The annulus end of the cylinder is supplied with PAS pump outlet pressure and the full area end of the cylinder is supplied with pressure regulated by the valve unit. The cylinder end of the piston rod is fitted with a piston which houses a piston seal.

The track rods are fitted with rubber bushes which are hard enough to give positive feel to the steering but at the same time reduce unwanted feedback through the track rod. Each track rod is fitted with a track rod end. The track rod end is a ball joint which locates on an extended bracket on the suspension strut and secured with a lock nut. A turnbuckle is screwed into the track rod and the track rod end and allows for the adjustment of the steering alignment.

The track rods are located on a bushed slider which locates on the rack. Two spacers are located between the slider and the track rods. Two flanged bolts secure the track rods to the rack.

VALVE UNIT

The valve unit is an integral part of the steering rack. The principal function of the valve unit is to provide maximum power assistance (i.e. when parking) with minimum effort required to turn the steering wheel.

The cast outer casing of the valve unit has four ports which provide the connections for pressure feed from the PAS pump, return to the fluid reservoir and pressure feeds from the valve unit to the annulus area and the full area of the cylinder. A non return valve and seal is fitted in the pressure feed port from the PAS pump. (Scheme 4)

Scheme 4

The valve unit comprises an outer sleeve, input shaft, torsion bar and a pinion shaft. The valve unit is coaxial with the pinion shaft which is connected to the steering column via the input shaft. The valve unit components are located in a housing which is attached to a mating casting on the steering rack main body and secured with screws.

The outer sleeve is located in the main bore of the valve unit. Three annular grooves are machined on its outer diameter. Polytetrafluorethylene (PTFE) rings are located between the grooves and seal against the bore of the valve unit. Holes are drilled radially in each annular groove through the wall of the sleeve. The bore of the outer sleeve is machined to accept the input shaft. Six equally spaced slots are machined in the bore of the sleeve. The ends of the slots are closed and do not continue to the ends of the outer sleeve. The radial holes in the outer sleeve are drilled into each slot.

The input shaft is splined at its outer end. The inner end of the input shaft forms a dog-tooth which mates with a slot in the pinion shaft. The fit of the dog-tooth in the slot allows a small amount of relative rotation between the input shaft and the pinion shaft before the dog-tooth contacts the wall of the slot. This ensures that, if the power assistance fails, the steering can be operated manually without over stressing the torsion bar. The central portion of the input shaft has equally spaced longitudinal slots machined in its circumference. The slots are arranged alternately around the input shaft.

The torsion bar is fitted inside the input shaft and is an interference fit in the pinion. The torsion bar is connected to the input shaft by a drive pin, fitted after hydraulic balancing. The central diameter of the torsion bar is machined to a smaller diameter than at each end. The smaller diameter allows the torsion bar to twist in response to torque applied from the steering wheel in relation to the grip of the tires on the road surface.

The pinion shaft has machined teeth on its central diameter which mate with the teeth on the steering rack. A slot machined in the upper end of the pinion shaft mates with the dog-tooth on the input shaft. The pinion shaft locates in a cast housing which is part of the steering rack and rotates on ball and roller bearings.

POWER ASSISTED STEERING (PAS) PUMP

The vane type PAS pump supplies hydraulic pressure to the steering rack valve unit. The PAS pump is driven by a Poly Vee belt from the crankshaft pulley. A self adjusting tensioner is fitted to maintain the correct belt tension.

The PAS pump comprises a body and cover which house the internal components of the pump. (Scheme 5) A pressure relief valve assembly is installed in the body. The relief valve also incorporates a flow control valve. The pressure relief valve limits the maximum pressure to between 120 and 127 bar (1740 and 1842 lbf/in 2 ) on KV6 and Td4 models. The flow control valve limits the maximum flow to between 5.0-6.0 L/min (1.32-1.58 US gal/min).

Scheme 5

A shaft runs longitudinally through the pump. One end of the shaft has a drive flange which accepts the drive pulley. The opposite end is closed by the cover. The shaft runs in bearings located in the body. Oil seals at each end of the shaft prevent the leakage of hydraulic fluid.

An oval cam ring is located in the body. Ten roller vanes are housed in a carrier and rotate within the cam ring. The carrier is mounted in the center of the shaft and receives positive drive from the shaft via a drive pin. The carrier is seated against an end plate which is located in the cover. The front of the carrier is covered by a port plate which is located against a seal plate in the body. The port plate controls the fluid flow into and out of the roller vanes during their cycle.

FLUID RESERVOIR

The fluid reservoir is mounted in the right hand side of the engine compartment on a bracket attached to the inner wing.

The reservoir comprises a body, a cap and a filter assembly. The reservoir has a capacity to the upper level mark of 335 cc. (Scheme 6)

Scheme 6

An "O" ring seal in the cap prevents leakage. The cap is pushed onto the latch and turned through 90° to lock. A breather hole is incorporated in the cap to allow changes in fluid level during operation.

A filter assembly is fitted into the bottom of the reservoir. The filter is made from fine nylon mesh which is molded into the frame of the filter. The filter removes particulate matter from the fluid before it is drawn into the supply connection and is non-serviceable.

The primary function of the fluid reservoir is to hold a surplus of hydraulic fluid in the system to allow for expansion and contraction of the fluid due to temperature variations. The fluid level ensures that the supply connection is covered with fluid at all operational attitudes. Any air that may be present in the hydraulic system will be exhausted from the fluid at the reservoir.

HIGH PRESSURE HOSE

The high pressure hose connecting the PAS pump to the valve unit incorporates an attenuator. The attenuator comprises a bullet shaped valve which is located between two spiral wound springs. The valve operates as a restrictor to damp pressure pulses from the PAS pump, reducing noise and strain on downstream components. The attenuator is integral with the hose and cannot be serviced separately.

PAS PUMP OPERATION

As the pump rotates, centrifugal force causes the roller vanes to move outwards in the slots in the carrier and contact the cam ring. As the carrier rotates, the cam ring form causes the space between the rollers to increase. The increasing volume between the roller vanes causes a depression which draws fluid into the space between the rollers. (Scheme 7)

Scheme 7

As the carrier continues to rotate, the inlet port is closed to the roller vanes which have drawn the fluid, trapping the fluid between the rollers. As the carrier rotates further, the cam form causes the space between the roller vanes to decrease, pressurizing the fluid between the rollers.

On further rotation of the carrier the roller vanes reach the discharge port and fluid is displaced under pressure from between the roller vanes into the discharge port. The space between each pair of rollers is subjected to this cycle twice for every revolution of the pump.

Pump Flow Control Valve Operation

The pump is a positive displacement type pump and potential output from the pump increases proportionally with engine speed. The flow control valve maintains a constant predetermined flow to the control unit regardless of engine speed. The flow control valve controls the flow of fluid and increases or decreases the flow discharged from the pump to compensate for engine speed variations. (Scheme 8)

Scheme 8

With the engine at idle the discharge flow from the pump is low and the full flow from the pump is delivered to the valve unit. As engine speed increases, the flow delivered by the pump increases proportionally. A pressure difference is created between each side of the metering orifice as the engine speed increases, the higher pressure being felt at the pump side of the metering orifice. This higher pressure is also felt at the top of the flow control valve via the recirculation passage. The lower pressure on the discharge side of the metering orifice is felt at the bottom of the flow control valve via the relief valve passage.

When the pressure at the top of the flow control valve exceeds the rating of the flow control valve spring, the valve begins to open against the spring pressure and the lower pressure at the discharge side of the metering orifice. Fluid is allowed to flow through the recirculation passage and recirculate through the pump.

As engine speed increases, the flow control valve is pushed down further, increasing the flow through the recirculation passage.

Pump Pressure Relief Valve Operation

The pressure relief valve is located in the center of the flow control valve. If the pressure on the discharge side of the metering orifice reaches a predetermined level, a spring loaded ball in the center of the valve will lift from its seat and allow pressurized fluid to recirculate within the pump. (Scheme 9)

Scheme 9

The pressure relief valve will operate if the discharge from the pump is restricted, steering held at full lock. If the discharge from the pump is completely blocked, all fluid discharged will be recirculated through the pump. As no fresh fluid is drawn into the pump from the reservoir, the fluid temperature inside the pump will increase quickly. Consequentially, periods of operation of full lock should be kept to a minimum to avoid overheating the pump and the fluid within it.

STEERING RACK OPERATION

Rotary movement of the steering wheel is transferred via the steering column to the input shaft of the valve unit on the steering rack. The rotary movement of the input shaft is converted into linear movement of the steering rack through the rack and pinion. With the engine running and the PAS pump operating, pressurized fluid is available to the steering rack for power assistance.

Neutral Position

With no movement of the steering wheel being applied, the slots in the outer sleeve and the input shaft are so aligned that the fluid flows across the valve unit with minimal restriction. Some pressure is applied to the full area port and the annulus port which in turn is felt at either side of the piston in the hydraulic cylinder. With the forces approximately equal on each side of the cylinder, the steering remains in the neutral position. Fluid delivered from the PAS pump is returned from the valve unit via the fluid cooler back to the reservoir. With minimal restriction across the valve unit and through the return hose, the pressure applied to each side of the piston is very low.

Right Steering (RHD Models; Left Steering on LHD Models)

Clockwise (on RHD, anti-clockwise on LHD) rotation of the steering wheel rotates the input shaft and the torsion bar in the same direction. The slots in the input shaft move out of their neutral alignment with the slots in the outer sleeve, as the torsion bar twists, and restricts the flow back to the reservoir. This restriction causes the supply pressure from the PAS pump to increase. The increased PAS pump pressure is directed to the annulus side of the hydraulic cylinder. Due to the relative displacement of the slots, the full area side of the cylinder is opened to return, producing a pressure difference across the piston. This results in a linear output force along the rack which provides the power assistance to turn the road wheels in the appropriate direction.

Left Steering (RHD Models; Right Steering on LHD Models)

Anti-clockwise (on RHD, clockwise on LHD) rotation of the steering wheel rotates the input shaft and the torsion bar in the same direction. The slots in the input shaft move out of their neutral alignment with the slots in the outer sleeve, as the torsion bar twists, and restricts the flow back to the reservoir. This restriction causes the supply pressure from the PAS pump to increase. The increased PAS pump pressure is directed to the annulus side of the hydraulic cylinder. Due to the relative displacement of the slots the increased PAS pump pressure is also applied to the full area side of the cylinder. The difference in effective areas on each side of the piston produces a linear output force along the rack which provides the power assistance to turn the road wheels in the appropriate direction.

Progressive Assistance

Progressive power assistance is dependent on the amount of road wheel resistance opposing the turning of the front wheels. When the steering wheel is turned to the left or right, the rotary movement is transferred through the steering column to the input shaft which rotates the same amount as the steering wheel. The rotary movement is also transferred from the input shaft to the torsion bar. If the road wheel resistance is high, e.g. when parking, the torsion bar will twist. The twisting of the torsion bar means that the rotary movement of the pinion and the outer sleeve is less than that of the input shaft.

The twisting of the torsion bar moves the slots in the input shaft and the torsion bar out of alignment. The greater the resistance of the road wheels to the steering rotary movement, the greater the misalignment of the slots in the input shaft and outer sleeve. As the misalignment becomes greater, the restriction in the return flow of fluid to the reservoir increases and therefore the fluid pressure applied to the hydraulic cylinder also increases. As the fluid pressure increases, so does the amount of assistance provided.

When the road wheel resistance reduces or less effort is applied to the steering wheel, the reduced torque applied to the input shaft allows the torsion bar to unwind. This reduces the misalignment between the slots in the input shaft and the outer sleeve, reducing the fluid pressure applied to the hydraulic cylinder and therefore the amount of assistance provided.

HYDRAULIC CIRCUIT OPERATION

When the engine is started, the PAS pump draws fluid from the reservoir down the low pressure suction line. The fluid passes through the PAS pump and emerges as pressurized fluid at the discharge port. The attenuated high pressure hose transports the pressurized fluid to the steering gear valve unit. (Scheme 10)

Scheme 10

If no steering effort is applied, there is minimal restriction within the system and the supply pressure from the pump is low. Minimal pressure is applied, via the valve unit, to each side of the piston in the hydraulic cylinder and the full flow from the PAS pump returns to the reservoir via the fluid cooler.

If steering effort is applied in either direction, the return flow of fluid to the reservoir is restricted, causing the supply pressure from the PAS pump to increase. The pressurized fluid is directed to the hydraulic cylinder, via the valve unit, providing power assistance to reduce the steering effort required. The fluid displaced by the movement of the piston in the cylinder is returned through the valve unit to the reservoir via the fluid cooler.

The fluid cooler reduces the fluid temperature which prolongs the life of the hoses and seals in the system.

Check

1. Switch off engine.
2. Check power steering fluid, if aerated, wait until fluid is free from bubbles then top-up reservoir to UPPER level mark. (Scheme 11)
3. Fit reservoir filler cap.

Adjust

1. Clean PAS fluid reservoir around filler cap and fluid level indicators.
2. Remove filler cap from reservoir and fill reservoir to UPPER mark with Dexron II D power steering fluid. Fluid must always be present in reservoir while bleeding.
3. Start engine and allow to run at idle for 10 seconds. Stop engine.
4. Top-up steering fluid reservoir.
5. Start engine and turn steering fully to LH and RH locks. Stop engine. CAUTION: DO NOT hold steering at full lock for longer than 10 seconds.
6. Top-up steering fluid reservoir.
7. Start and run engine for 2 minutes, turn steering fully to RH and LH locks.

1. Select position Park.
2. Remove key from starter switch.
3. Check that selector lever cannot be moved from Park position.
4. Insert and turn key to position II.
5. Depress brake pedal and check that selector lever can be moved from Park position, and key cannot be removed from starter switch. Key should only rotate back to a position between positions I and 0.

1. Select Park position.
2. Remove key from starter switch.
3. Remove front console. See «76.25.01 CONSOLE - FRONT - UP TO 04MY»(/land-rover/freelander/l314-2003-2006/remont/exteriorinterior-trim/#interior-trim__762501-console-front-up).
4. Loosen bolt securing cable clamp. (Scheme 12)
5. Pull cable away from interlock mechanism until spring pressure is felt. Correct adjustment is cable free play removed without compressing spring. When correct tighten interlock cable clamp screw to 6 Nm (4.5 ft. lbs).
6. Recheck cable operation.
7. Fit front console. See «76.25.01 CONSOLE - FRONT - UP TO 04MY»(/land-rover/freelander/l314-2003-2006/remont/exteriorinterior-trim/#interior-trim__762501-console-front-up).

FRONT WHEEL ALIGNMENT - CHECK & ADJUST

For front wheel alignment specifications and procedures, see SPECIFICATIONS & PROCEDURES article.

ALIGNMENT - REAR WHEEL - CHECK & ADJUST

For rear wheel alignment specifications and procedures, see SPECIFICATIONS & PROCEDURES article.

1. Position absorbent cloth to catch spillage.
2. Remove bolt securing PAS high pressure pipe clip to PAS pump.
3. Loosen union securing high pressure pipe to PAS pump and release pipe.
4. On K1.8 models: Fit adaptor LRT-57-034A to high pressure port of PAS pump.
5. On KV6 & Td4 models: Fit adaptor LRT-57-042 to high pressure port of PAS pump. (Scheme 13)
6. Fit adaptor LRT-57-035 to existing high pressure hose.
7. Fit hose LRT-57-002 to each adaptor.
8. Fit pressure gauge LRT-57-005 to test valve LRT-57-001.
9. Connect hoses LRT-57-002 to LRT-57-001 and tighten unions.
10. Ensure steering system and test equipment is free from leaks.
11. Maintain maximum fluid level during test.
12. With the test valve open, start the engine.
13. Pressure at idle should be between 5-7 bar (72.5-101.5 psi).
14. With the engine at idle, slowly turn the steering wheel and hold on full lock.
15. Repeat procedure for other side.
16. Test pressure should rise significantly as steering wheel is rotated and continue to rise as full lock is approached. Full lock pressures should be 90-100 bar (1305-1450 psi). NOTE: Maximum operating pressure is limited by pressure relief valve in pump.
17. With the engine at idle, release steering wheel. Idle pressure 5-7 bar (72.5-101.5 psi).
18. Pressures outside the above tolerance indicates a fault.
19. To determine if fault is in steering pump or steering rack, close the test valve for a maximum of 5 seconds. CAUTION: Pump damage will occur if test valve is closed for longer periods.
20. If gauge does not register correct reading, suspect faulty pump.
21. If PAS pump pressure is correct and steering is heavy at idle and becomes light as engine RPM is increased, suspect pump flow rate.
22. If maximum pump pressure is correct, suspect steering rack.
23. On completion stop engine and remove test equipment.
24. Clean PAS pump and pipe union.
25. Fit NEW "O" ring to high pressure pipe, align to PAS pump and tighten union to 25 Nm (18 ft. lbs).
26. Fit bolt securing high pressure pipe clip and tighten to 8 Nm (6 ft. lbs).
27. Check and top-up PAS fluid level. See «POWER ASSISTED STEERING (PAS) SYSTEM - BLEED»(/land-rover/freelander/l314-2003-2006/remont/manual-power-steering/#steering-system).

Scheme 11

1. Raise and support front of vehicle. WARNING: DO NOT work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
2. Remove front road wheels.
3. Remove and discard nuts securing track rod ball joints to steering arms. (Scheme 14)
4. Fit an M12 nut to each ball pin, flush with end of each pin.
5. Using LRT-57-043, separate ball pins from RH and LH steering arms. Remove M12 nuts and release ball pins from steering arms.
6. Remove pinch bolt securing steering column to PAS rack pinion. see scheme 15
7. On KV6 models: Remove 2 nuts securing steering rack heat shield and remove heat shield. see scheme 16
8. On KV6 models: Remove 2 bolts securing coolant rail to cylinder block.
9. On Td4 manual models: Using tool LRT-37-050 release gear change rods from gear change linkage. see scheme 17
10. On Td4 manual models: Remove 2 bolts securing gear-change linkage to bulkhead and tie aside.
11. On Td4 manual models: Remove bolt securing IRD coolant hose "P" clip. see scheme 18
12. On Td4 auto models: Remove bolt securing IRD coolant hose "P" clip. see scheme 19
13. On Remove 2 bolts and washers securing PAS rack clamp to bulkhead, discard bolts. see scheme 20
14. Remove PAS rack clamp.
15. Remove rubber mount.
16. Remove and discard 2 bolts securing PAS rack mounting to bulkhead. see scheme 21
17. Release PAS rack pinion from steering column.
18. Position container to collect PAS fluid spillage.
19. Remove bolt securing pipe bracket to PAS rack. see scheme 22
20. Release pipe unions and disconnect fluid pipes from PAS rack. CAUTION: Always fit plugs to open connections to prevent contamination.
21. Remove and discard "O" rings.
22. Remove bolt securing PAS pipes to clamp and loosen clamp bolt.
23. KV6 models: Remove RH Hydramount and lower engine to aid rack removal. See «HYDRAMOUNT - ENGINE - RIGHT»(ref-158807-S34126241132005011200000).
24. With assistance remove PAS rack from passenger side of vehicle.
25. Remove dust seal from pinion housing. see scheme 23

Installation

1. Fit PAS rack to vehicle from passengers side.
2. Fit dust shield to pinion housing.
3. On KV6 models: Fit RH Hydramount. See «HYDRAMOUNT -- ENGINE -- RIGHT»(ref-158807-S34126241132005011200000) .
4. Ensure pipe unions are clean.
5. Fit NEW "O" rings to fluid pipes.
6. Fit fluid pipes to PAS rack but do not tighten at this stage.
7. Align fluid pipe bracket to PAS rack, fit bolt but do not tighten at this stage.
8. With assistance fit PAS rack pinion to steering column, ensuring column coupling is aligned with gear input flag.
9. Fit washers and new bolts securing steering rack mounting to bulkhead, but do not tighten at this stage. Ensure large washer is fitted to lower bolt.
10. Fit rubber mount and clamp to PAS rack.
11. Fit bolts securing clamp to bulkhead but do not tighten at this stage.
12. Tighten PAS rack mounting bolts to 45 Nm (33 ft. lbs).
13. Tighten PAS rack clamp bolts to 45 Nm (33 ft. lbs).
14. Tighten PAS rack fluid feed pipe union to 18 Nm (13 ft. lbs).
15. Tighten PAS rack fluid return pipe union to 22 Nm (16 ft. lbs).
16. Tighten fluid pipe bracket to 10 Nm (7 ft. lbs).
17. Align PAS rack clamp and tighten bolt.
18. Align pipes to clamp fit bolt and tighten to 10 Nm (7 ft. lbs).
19. Fit pinch bolt to steering column and tighten to 32 Nm (24 ft. lbs). CAUTION: Nuts and bolts must be tightened with the weight of the vehicle on the suspension.
20. Ensure tapers in track rod end and steering arm are clean and rubber boot is not damaged.
21. Fit ball joints to steering arms, fit new nuts and tighten to 55 Nm (40 ft. lbs).
22. On KV6 models: Align coolant rail to cylinder block, fit bolts and tighten to 10 Nm (7 ft. lbs).
23. On KV6 models: Position heat shield, fit nuts and tighten to 25 Nm (18 ft. lbs).
24. On Td4 manual models: Align IRD hose "P" clip fit bolt and tighten to 25 Nm (18 ft. lbs).
25. On Td4 manual models: Align gear-change linkage to bulkhead, fit bolts and tighten to 25 Nm (18 ft. lbs).
26. On Td4 manual models: Connect gear change rods to gear change linkage.
27. On Td4 auto models: Align IRD hose "P" clip fit bolt and tighten to 25 Nm (18 ft. lbs).
28. Fit road wheel(s) and tighten nuts to 115 Nm (85 ft. lbs).
29. Remove stands and lower vehicle.
30. Bleed PAS system. See «POWER ASSISTED STEERING (PAS) SYSTEM - BLEED»(/land-rover/freelander/l314-2003-2006/remont/manual-power-steering/#steering-system) .
31. Check and adjust front wheel alignment. See «FRONT WHEEL ALIGNMENT - CHECK & ADJUST»(/land-rover/freelander/l314-2003-2006/remont/manual-power-steering/#steering-system__front-wheel-alignment-check) .

Removal

1. Remove PAS rack. See «POWER STEERING RACK»(/land-rover/freelander/l314-2003-2006/remont/manual-power-steering/#steering-system).
2. Hold PAS rack securely and remove 2 Torx bolts securing track rods. Discard bolts. see scheme 24
3. Remove support plate.
4. Remove track rods and spacers. CAUTION: Note orientation of spacers before dismantling.
5. Remove clips from PAS rack ram feed pipes. see scheme 25
6. Loosen 4 pipe unions and remove both ram feed pipes. CAUTION: Always fit plugs to open connections to prevent contamination.
7. Remove clamp bolt from fluid pipe support bracket and remove bracket.
8. Remove 2 gaiter securing clips.
9. Remove gaiter sealing ring.
10. Remove gaiter.
11. Remove gaiter sealing band.
12. Remove slider and clip assembly.
13. Remove clip from slider.

1. Clean remains of lubricant from PAS rack slider and clip.
2. Fit clip to slider and fit slider assembly to PAS rack.
3. Apply grease supplied in the gaiter kit to exposed rack shaft, slider and clip.
4. Fit gaiter sealing band.
5. Fit gaiter.
6. Fit gaiter sealing ring.
7. Align gaiter to slider and having ensured slider is correctly located, use track rod securing bolts to hold gaiter in position, without tightening bolts, so to activate Loctite. CAUTION: DO NOT screw bolts in more than 4 or 5 turns.
8. Ensure gaiter is not twisted, and fit gaiter securing clips.
9. Fit fluid pipe support bracket and secure with bolt.
10. Ensure pipe unions and rack ports are clean.
11. Fit both ram feed pipes and tighten small diameter pipe to 18 Nm (13 ft. lbs) and large diameter pipe to 24 Nm (18 ft. lbs).
12. Fit clips to pipes.
13. Remove track rod bolts securing bolts used to align gaiter, fit spacers, track rods and support plate to PAS rack. CAUTION: Ensure spacers are aligned and fitted correctly.
14. Hold track rods parallel with PAS rack and tighten new Torx bolts to 100 Nm (74 ft. lbs). see scheme 26
15. Fit PAS rack. See «POWER STEERING RACK»(/land-rover/freelander/l314-2003-2006/remont/manual-power-steering/#steering-system).

1. Remove front bumper on models up to 2004 model year.
2. Position container below PAS pipes to catch fluid spillage.
3. Using LRT-57-044 release and disconnect PAS hoses from oil cooler. see scheme 27
4. Remove 2 bolts and remove PAS fluid cooler.

1. Fit fluid cooler and tighten bolts to 10 Nm (7 ft. lbs).
2. Clean connections.
3. Connect hoses to fluid cooler.
4. Fit front bumper on models up to 2004 model year.
5. Bleed PAS system. See «POWER ASSISTED STEERING (PAS) SYSTEM - BLEED»(/land-rover/freelander/l314-2003-2006/remont/manual-power-steering/#steering-system) .

1. Disconnect battery earth lead.
2. Remove engine mounting top arm. See «ARM ASSEMBLY - ENGINE MOUNTING RIGHT»(ref-158807-S14546723542005011200000).
3. Loosen PAS pump pulley bolts. see scheme 28
4. Using a 3/8" socket bar, raise ancillary drive belt tensioner and release drive belt from alternator and PAS pump pulleys. see scheme 29
5. Position container to collect PAS fluid spillage.
6. Release clip and disconnect fluid inlet hose from PAS pump. see scheme 30
7. Remove banjo bolt securing fluid outlet hose to PAS pump, release hose, remove and discard sealing washers. see scheme 30 CAUTION: To prevent damage to components, use two spanners when loosening or tightening unions.
8. Remove bolt securing PAS outlet pipe support bracket to cylinder head and move pipe aside.
9. Remove 3 bolts securing PAS pump pulley to PAS pump and remove pulley. see scheme 31 CAUTION: Always fit plugs to open connections to prevent contamination.
10. Remove 3 bolts securing PAS pump to mounting bracket. see scheme 32
11. Remove PAS pump.

1. Position PAS pump and align to mounting bracket.
2. Fit bolts securing PAS pump to mounting bracket and tighten to 25 Nm (18 ft. lbs).
3. Fit PAS pump pulley to PAS pump and tighten bolts to finger tight.
4. Remove plug from fluid outlet hose.
5. Clean banjo bolt and mating faces.
6. Using new sealing washers, fit PAS outlet hose to pump and tighten banjo bolt to 20 Nm (15 ft. lbs). CAUTION: To prevent damage to components, use two spanners when loosening or tightening unions.
7. Align outlet pipe clip. Fit bolt and tighten to 22 Nm (16 ft. lbs).
8. Clean elbow on PAS pump.
9. Remove plug from fluid inlet hose, fit new clip and connect hose to PAS pump.
10. Remove container.
11. Clean pulley and tensioner pulley running surface.
12. Using a 3/8" square drive socket bar, raise ancillary drive belt tensioner and fit drive belt to pulleys.
13. Tighten PAS pump pulley bolts to 10 Nm (7.5 ft. lbs).
14. Fit engine mounting top arm. See «ARM ASSEMBLY - ENGINE MOUNTING RIGHT»(ref-158807-S14546723542005011200000) .
15. Connect battery earth lead.
16. Bleed PAS system. See «POWER ASSISTED STEERING (PAS) SYSTEM - BLEED»(/land-rover/freelander/l314-2003-2006/remont/manual-power-steering/#steering-system) .

1. Remove key from starter switch.
2. Carefully remove upper half of nacelle. Take care when releasing clips from lower half of nacelle. see scheme 33
3. Remove 2 screws securing lower nacelle to steering column.
4. Lower steering column tilt lever.
5. Carefully remove cover from starter switch being careful not to damage the passive coil.
6. Carefully pull lower half of nacelle from retaining clip on column lock.

1. Ensure that the steering column tilt lever is lowered.
2. Position lower half of nacelle and engage with clip on column lock.
3. Raise column tilt lever.
4. Fit and tighten 2 screws securing lower half of nacelle to steering column.
5. Fit cover to starter switch.
6. Fit upper half of nacelle and ensure that clips engage with lower half.

1. Disconnect battery earth lead.
2. Remove starter key from ignition lock.
3. Remove steering column nacelle. See «NACELLE - COLUMN»(/land-rover/freelander/l314-2003-2006/remont/manual-power-steering/#steering-system).
4. Disconnect multiplugs from ignition switch and passive coil. see scheme 34
5. Remove passive coil. see scheme 35
6. Remove 2 screws and remove ignition switch.
7. Move rubber column cover aside to access column lock bolts.
8. Mark both column lock bolts using a center punch.
9. Drill out both column lock bolts.
10. Remove column lock saddle and remove column lock.
11. On models with automatic transmission: Loosen union and release key interlock cable from column lock. see scheme 36

1. On models with automatic transmission: Align key interlock cable to column lock and tighten union to 4 Nm (3 ft. lbs).
2. Position lock to steering column assembly and fit shear bolts. DO NOT tighten shear bolts at this stage.
3. Insert starter key, check operation of steering lock and that key turns freely.
4. Ensure correct operation of key interlock cable.
5. Remove starter key from column lock.
6. Tighten shear bolts fully and shear heads off.
7. Position ignition switch to column, fit and tighten screws.
8. Fit passive coil.
9. Connect multiplugs to ignition switch and passive coil.
10. On models with automatic transmission: Ensure correct operation of microswitch.
11. Align column cover.
12. Fit steering column nacelle. See «NACELLE - COLUMN»(/land-rover/freelander/l314-2003-2006/remont/manual-power-steering/#steering-system) .
13. Connect battery earth lead.

1. Disconnect battery earth lead.
2. Remove front console. See «76.25.01 CONSOLE - FRONT - UP TO 04MY»(/land-rover/freelander/l314-2003-2006/remont/exteriorinterior-trim/#interior-trim__762501-console-front-up).
3. Loosen bolt securing cable clamp. see scheme 37
4. Disconnect cable from interlock mechanism.
5. Remove key from starter switch.
6. Remove steering column nacelle. See «NACELLE - COLUMN»(/land-rover/freelander/l314-2003-2006/remont/manual-power-steering/#steering-system).
7. Remove bolt securing steering column height adjuster lever and remove lever. see scheme 38 NOTE: Thread is left handed.
8. Remove nut securing height adjuster clamp bolt and remove bolt.
9. Collect plastic stop.
10. Loosen union and disconnect cable from column lock. see scheme 36
11. Release cable from 2 retaining clips. see scheme 39
12. Note the cable routing, maneuver cable from under heater and steering column bracket.
13. Remove cable.

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 ft. lbs).
3. Fit height adjuster clamp bolt and tighten nut to 10 Nm (7.5 ft. lbs). Ensure bolt and plastic stop are correctly located in slot in column bracket.
4. Fit height adjuster lever and tighten bolt 12 Nm (9 ft. lbs). 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. See «CABLE - KEY INTERLOCK - ADJUST»(/land-rover/freelander/l314-2003-2006/remont/manual-power-steering/#steering-system) .
7. Fit steering column nacelle. See «NACELLE - COLUMN»(/land-rover/freelander/l314-2003-2006/remont/manual-power-steering/#steering-system) .
8. Fit front console. See «76.25.01 CONSOLE - FRONT - UP TO 04MY»(/land-rover/freelander/l314-2003-2006/remont/exteriorinterior-trim/#interior-trim__762501-console-front-up) .
9. Connect battery earth lead.

1. Disconnect battery earth lead.
2. Remove steering column multi purpose switch. See «86.65.55 SWITCH - COMBINED DIRECTION INDICATOR HEADLIGHT HORN»(/land-rover/freelander/l314-2003-2006/remont/exterior-lights/#lighting__866555-switch-combined-direction-indicator).
3. Disconnect multiplugs from ignition switch and passive coil. see scheme 40
4. Remove 2 screws securing steering column aperture trim and remove trim. see scheme 41
5. Lower glove lid and remove fuse box cover. see scheme 42
6. Carefully cut 2 harness clips from LH side of column and release harness. see scheme 43
7. Release 2 harness clips from RH side of column and release harness.
8. On models with automatic transmission: Release key interlock cable from column clip. see scheme 44
9. On models with automatic transmission: Loosen union and release key interlock cable from column lock. see scheme 36
10. On models with automatic transmission: Remove bolt securing steering column height adjuster lever and remove lever. see scheme 45
11. On models with automatic transmission: Remove nut securing height adjuster clamp bolt and remove bolt.
12. On models with automatic transmission: Release key interlock cable from steering column.
13. On models with automatic transmission: Fit clamp bolt and nut to retain support bracket in position.
14. Remove pinch bolt securing steering column to PAS rack pinion. see scheme 46
15. Remove bolt securing steering column to fusebox support bracket.
16. Remove 2 nuts and 2 bolts securing steering column to fascia support rail. see scheme 47
17. Collect snubber.
18. Release steering column from support bracket and PAS rack pinion.
19. Remove steering column assembly.
20. Remove 2 cable ties from steering column.
21. Remove key interlock cable clip.
22. Remove 2 screws securing ignition switch and remove ignition switch. see scheme 48
23. Remove passive coil.
24. Position steering column assembly in a vice.
25. Center punch or drill out steering lock shear bolts. CAUTION: If steering column is to be re-used, take care not to deform or damage column in vice.
26. Remove steering column lock. CAUTION: Take care not to damage steering lock body if the lock is to be refitted.

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 ft. lbs).
7. Tighten nuts to 14 Nm (10 ft. lbs).
8. Fit and tighten PAS rack pinion clamp bolt to 32 Nm (24 ft. lbs). CAUTION: Nuts and bolts must be tightened with weight of vehicle on suspension.
9. On models with automatic transmission: Remove clamp bolt from height adjuster and position key interlock cable.
10. On models with automatic transmission: Fit height adjuster clamp bolt and tighten nut to 10 Nm (7.5 ft. lbs). Ensure bolt and plastic stop are correctly located in slot in column bracket.
11. On models with automatic transmission: Fit height adjuster lever and tighten bolt 12 Nm (9 ft. lbs). Ensure lever is in the fully up position before tightening bolt. Hold clamp bolt nut to prevent nut rotation.
12. On models with automatic transmission: Remove starter key from column lock.
13. On models with automatic transmission: Align key interlock cable to column lock and tighten union to 4 Nm (3 ft. lbs).
14. On models with automatic transmission: Position lock to steering column assembly and fit shear bolts. Do not tighten shear bolts at this stage.
15. On models with automatic transmission: Insert starter key, check operation of steering lock and that key turns freely.
16. On models with automatic transmission: Ensure correct operation of key interlock cable.
17. On models with automatic transmission: Remove starter key from column lock.
18. On models with automatic transmission: Tighten shear bolts fully and shear heads off.
19. On models with automatic transmission: Fit passive coil.
20. On models with automatic transmission: Position ignition switch to column, fit and tighten screws.
21. On models with automatic transmission: Secure key interlock cable in clip.
22. On models with automatic transmission: Ensure key interlock cable is correctly fitted.
23. Fit side support bolt and tighten to 10 Nm (7.5 ft. lbs).
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. See «86.65.55 SWITCH - COMBINED DIRECTION INDICATOR HEADLIGHT HORN»(/land-rover/freelander/l314-2003-2006/remont/exterior-lights/#lighting__866555-switch-combined-direction-indicator) .
29. Connect battery earth lead.

Scheme 12

Scheme 13

1. Raise and support front of vehicle. WARNING: DO NOT work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
2. Remove front road wheel.
3. Remove pinch bolt securing ball joint to turnbuckle. see scheme 49
4. Remove nut from ball joint and discard.
5. Fit an M12 nut to ball joint, flush with end of pin.
6. Using tool LRT-57-043, separate ball joint from steering arm. Remove M12 nut and release ball joint from steering arm.
7. Remove ball joint, note the number of turns for refit. see scheme 50

1. Fit ball joint to turnbuckle to number of turns noted in remove.
2. Fit pinch bolt but do not tighten at this stage.
3. Clean ball joint taper and taper seat.
4. Fit ball joint to steering arm, fit new nut and tighten to 55 Nm (41 ft. lbs). see scheme 51 CAUTION: Ensure slots in turn buckle clamps are aligned.
5. Fit road wheel(s) and tighten nuts to 115 Nm (85 ft. lbs).
6. Remove stands and lower vehicle.
7. Check and adjust front wheel alignment. See «WHEEL ALIGNMENT SPECIFICATIONS»(/land-rover/freelander/l314-2003-2006/remont/wheel-alignment/#specifications-procedures__wheel-alignment-specifications). WARNING: Ensure all track rod pinch bolts are tightened to the correct torque on completion of the front wheel alignment check.

Scheme 14

1. Remove steering rack. See «POWER STEERING RACK»(/land-rover/freelander/l314-2003-2006/remont/manual-power-steering/#steering-system).
2. Remove Torx bolt securing track rod to PAS rack. Discard Torx bolt. see scheme 24
3. Remove track rod and spacer. CAUTION: Note orientation of spacers before dismantling.
4. Hold track rod securely and loosen pinch bolt in track rod end. see scheme 52 NOTE: DO NOT carry out further dismantling if component is removed for access only.
5. Remove ball joint, note the number of turns for refit.
6. Remove pinch bolt from track rod.
7. Remove turnbuckle and note the number of turns for refit. NOTE: Thread is left handed.

1. Fit turnbuckle to track rod to number of turns on remove.
2. Fit pinch bolt but do not tighten at this stage.
3. Fit ball joint to turnbuckle to number of turns noted in remove.
4. Fit pinch bolt but do not tighten at this stage. see scheme 51 CAUTION: Ensure slots in turn buckle clamps are aligned.
5. Clean spacer, support plate and track rod ball joint.
6. Fit spacer to rack. see scheme 26 CAUTION: Ensure spacers are aligned and fitted correctly.
7. Fit track rod to PAS rack.
8. Hold track rod parallel to PAS rack, fit new Torx bolt and tighten to 100 Nm (74 ft. lbs).
9. Fit steering rack. See «POWER STEERING RACK»(/land-rover/freelander/l314-2003-2006/remont/manual-power-steering/#steering-system).
10. Check and adjust front wheel alignment. See «FRONT WHEEL ALIGNMENT - CHECK & ADJUST»(/land-rover/freelander/l314-2003-2006/remont/manual-power-steering/#steering-system__front-wheel-alignment-check). WARNING: Ensure all track rod pinch bolts are tightened to the correct torque on completion of the front wheel alignment check.

1. Remove driver side airbag module from steering wheel: For 2002 models, see «DRIVER-SIDE AIR BAG MODULE»(ref-150749-S23140253802002112100000) article. For 2003 models, see «DRIVER-SIDE AIR BAG MODULE»(ref-160441-S29025151922004021000000) article. For 2004-05 models, see «DRIVER-SIDE AIR BAG MODULE»(ref-150749-S23140253802002112100000) article.
2. Disconnect multiplug from rotary coupler. see scheme 53
3. Centralize steering wheel with road wheels in straight ahead position.
4. Restrain steering wheel and loosen self locking nut securing steering wheel to column.
5. Pull steering wheel from column splines.
6. Remove and discard self-locking nut.
7. Remove steering wheel.
8. Attach tape across edge of rotary coupler to retain correct setting. see scheme 54
9. On Td4 models: Remove 3 screws securing damper and remove damper. see scheme 55
10. Using a broad round edged tool, carefully pry horn switches from steering wheel. see scheme 56
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. see scheme 57
14. Release harness from clips and remove harness.
15. On models with cruise control: Remove 2 screws securing cruise control switches to steering wheel.
16. On 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.

1. Fit radio switches to steering wheel and secure with screws.
2. On 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. On 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 ft. lbs).
12. Connect multiplug to rotary coupler.
13. Fit driver side airbag: For 2002 models, see «DRIVER-SIDE AIR BAG MODULE»(ref-150749-S23140253802002112100000) article. For 2003 models, see «DRIVER-SIDE AIR BAG MODULE»(ref-160441-S29025151922004021000000) article. For 2004-05 models, see «DRIVER-SIDE AIR BAG MODULE»(ref-150749-S23140253802002112100000) article.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• 76.25.01 CONSOLE - FRONT - UP TO 04MY
• SPECIFICATIONS & PROCEDURES
• 86.65.55 SWITCH - COMBINED DIRECTION INDICATOR HEADLIGHT HORN
• WHEEL ALIGNMENT SPECIFICATIONS
• POWER ASSISTED STEERING (PAS) SYSTEM - BLEED
• FRONT WHEEL ALIGNMENT - CHECK & ADJUST