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    1999 Chrysler Truck Town & Country AWD 3.8L MFI 6cyl

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    Land Rover 2000-05

    Removal & Installation 1

    Print

    Freelander (2001-04)



    1. Drain cooling system.
    2.  
    3. Release 2 clips securing heater hoses to heater and disconnect hoses.
    4.  
    5. Remove dash panel by the following steps:
      1. Remove front console
      2.  
      3. Remove rotary couple for air bag system:
      4.  



      Steering wheel centered and road wheels straight ahead
       
      Remove steering wheel
       
      Remove steering column covers
       
      Disconnect 2 multiplugs from rotary coupler
       
      Remove 4 screws and remove rotary coupler
       
      Remove the 4 multiplugs from the wiper/indicator switch.
       
      Loosen the clamping screw and remove the wiper/indicator switch.
       
      Remove the 2 screws from the steering column lower finish panel and remove panel.
       
      Open the driver side glove box lid and remove the fuse box cover.
       
      Disconnect 2 multiplugs from the fuse box. Close the glove box.
       
      Remove the clock.
       
      Remove the upper trim panels from both A-pillars.
       
      Remove the passenger side airbag module by removing or disconnecting the following:
       
      2 screws holding airbag lower finish panel
       
      4 Torx bolts hold airbag module to dash panel
       
      Airbag connector from airbag module
       
      Remove airbag module and store properly
       
      Disconnect the 2 main harness-to-dash multiplugs through the center console opening.
       
      Remove the 12 dash panel retaining bolts.
       
      With an assistant, carefully remove the dash panel.
       

    6.  
    7. Remove the 2 bolts from the console support bracket, release the 2 relays and remove the brackets from in front of the shift lever.
    8.  
    9. Disconnect the 4 multiplugs from the heater controls.
    10.  
    11. Disconnect the multiplug from the heater assembly and release the diagnostic connector.
    12.  
    13. Disconnect the multiplug from the evaporator.
    14.  
    15. Disconnect the ducts from the left and right outer face level vents.
    16.  
    17. Detach the left and right defogger vents.
    18.  
    19. Release the air inlet connector hose.
    20.  
    21. Disconnect the harness from the heater housing.
    22.  
    23. Remove 2 nuts and 1 bolt and remove the heater assembly.
    24.  


    NOTE
    Do not carry out further dismantling if component is removed for access only.

    1. Disconnect the 2 multiplugs from the heater controls.
    2.  
    3. Release the air blend control cable from the lever and abutment.
    4.  
    5. Release the air distribution cable from the lever and abutment.
    6.  
    7. Remove the heater controls.
    8.  
    9. Remove screw securing pipe clamp to the heater casing and remove clamp.
    10.  
    11. Remove 2 screws from core cover and remove cover.
    12.  
    13. Remove the heater core.
    14.  

    To install:



    Fit the heater core to the heater assembly.
     
    Fit the core cover and secure with screws.
     
    Fit pipe clamp and secure with screw.
     
    Install the heater assembly.
     
    Position the heater controls to replacement heater, if necessary.
     
    Connect the air distribution cable to lever and abutment.
     
    Connect the air blend cable to lever and abutment.
     
    Connect the multiplugs to heater controls.
     
    Position the heater and secure with nuts and bolt.
     
    Position harness and connect to clips on heater.
     
    Fit the air inlet connector hose.
     
    Fit the right side defogger vent duct to heater.
     
    Fit the right side outer face level vent duct to heater and secure to body with bolt.
     
    Fit the left side defogger vent duct to heater.
     
    Fit left side outer face level vent duct to heater and secure to body with bolt.
     
    Connect the multiplug to evaporator.
     
    Connect the multiplug to the heater and secure the diagnostic socket.
     
    Connect the multiplugs to heater controls.
     
    Fit console support bracket and secure with bolts.
     
    Fit relays to console support bracket.
     
    Install the dash panel in reverse of the removal procedure.
     


    CAUTION
    Use special care to ensure the airbag module is properly restored.

    1. Connect the heater hoses and secure with clips.
    2.  
    3. Refill the cooling system.
    4.  
    5. Operate the engine to normal operating temperatures. Test the controls and check for leaks.
    6.  


      Click image to see an enlarged view

      Fig. Removing passenger airbag module-Freelander



      Click image to see an enlarged view

      Fig. Identifying key components on the heater assembly-Freelander


    Discovery (2001-04)



    1. Disconnect the negative (-) battery cable, then disconnect the positive (+) battery cable.
    2.  


    NOTE
    Remove the key from the ignition switch and wait 10 minutes before starting work to allow system airbags to fully discharge.

    1. Drain the cooling system into a clean container for reuse.
    2.  
    3. Discharge and recover the air conditioning system refrigerant.
    4.  
    5. Detach the heater hoses from the firewall connections.
    6.  
    7. Disconnect A/C refrigerant pipes from the evaporator fittings at the firewall and discard the O-rings.
    8.  
    9. Remove the dash panel assembly by performing the following procedure:
      1. Remove the stereo (radio/cassette/CD) player, using special tools as shown.
      2.  
      3. Remove the steering wheel.
      4.  
      5. Remove the steering column cover.
      6.  
      7. Remove the center console assembly.
      8.  
      9. Remove the A-pillar trim panels.
      10.  
      11. Remove the passenger and driver side lower trim panels.
      12.  
      13. Disconnect the multiplugs from the switches in the instrument cowl and remove the cowl.
      14.  
      15. Remove the instrument cluster.
      16.  
      17. Remove the glove box.
      18.  
      19. Disconnect the multiplug from the heater controls.
      20.  
      21. From the glove box opening, separate the Blue multiplug and release the coaxial cables from the dash panel.
      22.  
      23. Disconnect the multiplug from the passenger air bag.
      24.  
      25. Disconnect the blower motor.
      26.  
      27. Through the glove box opening, remove the passenger air bag assembly.
      28.  
      29. Remove bolts holding the dash panel at the transmission tunnel and at the A-pillars.
      30.  
      31. With an assistant, carefully remove the dash panel from the vehicle.
      32.  

    10.  
    11. Remove the 4 screws securing the rear heater ducting and remove the ducting from along the center.
    12.  
    13. Remove the 2 blower motor housing nuts and bolt and remove the blower motor from the heater housing.
    14.  
    15. Remove the 2 center console front mounting bracket-to-chassis bolts and remove the center console front mounting bracket.
    16.  
    17. Remove the 2 nuts holding the right dash panel support bracket and remove the bracket.
    18.  
    19. Disconnect both drain tubes.
    20.  
    21. Remove the front heater ducting.
    22.  
    23. Remove the 4 nuts and bolt holding the heater assembly. Remove the heater by detaching it from the bulkhead grommet.
    24.  


      Click image to see an enlarged view

      Fig. Removing stereo system from dash-Discovery



      Click image to see an enlarged view

      Fig. Disconnecting blue multiplug and coaxial cables-Discovery


    To install:

    1. Position the heater assembly to bulkhead, fixing the heater tubes into the bulkhead grommet.
    2.  
    3. Install the heater assembly nuts and bolt and torque to 12 ft. lbs. (16 Nm).
    4.  
    5. Position right dash panel support bracket and install and tighten nuts.
    6.  
    7. Install the front heater ducting.
    8.  
    9. Position the center console support bracket and tighten retaining screws.
    10.  
    11. Connect both drain tubes.
    12.  
    13. Install the heater motor to its casing. Install and tighten the nuts and bolt to 14 ft. lbs. (19 Nm).
    14.  
    15. Connect the multiplug for the heater motor.
    16.  
    17. Install the rear heater ducting and secure with screws.
    18.  
    19. Install the dash panel assembly by performing the following procedure:
      1. Using an assistant, install the dash panel assembly to the vehicle. Install and tighten the lower edge bolts to 19 ft. lbs. (26 Nm).
      2.  
      3. Install and tighten the bolts retaining the instrument panel to the frame to 19 ft. lbs. (26 Nm).
      4.  
      5. Install the instrument panel-to-steering column bracket nuts and tighten to 8 ft. lbs. (11 Nm).
      6.  
      7. Secure the coaxial cables to the instrument panel and secure the blue multiplug to the main ICE multiplug, working through the glove box opening.
      8.  
      9. Connect the heater control multiplug connector.
      10.  
      11. Connect the multiplugs for the blower motor and for the passenger air bag.
      12.  
      13. Install the glove box and secure with bolts.
      14.  
      15. Connect the dash multiplugs to the main harness and to the fuse box.
      16.  
      17. Position to instrument cluster and connect the multiplugs, then install the cluster assembly with its screws.
      18.  
      19. Install the instrument cluster cowl, connecting the multiplugs to the cowl switches.
      20.  
      21. Working below the steering column, install the driver-s side access panel.
      22.  
      23. Install both lower closing panels and secure with their clips.
      24.  
      25. Install both dash panel mats.
      26.  
      27. Install the center console assembly.
      28.  
      29. Install the steering column covers, then install the steering wheel, using a new self-locking nut torqued to 32 ft. lbs. (43 Nm).
      30.  
      31. Install the radio assembly.
      32.  

    20.  
    21. Use new O-rings and insert the A/C pipes into the evaporator. Tighten the bolts to 2.7 ft. lbs. (5 Nm).
    22.  
    23. Connect the heater hoses and install the clamps at the firewall.
    24.  
    25. Evacuate and charge the air conditioning system.
    26.  
    27. Refill the cooling system.
    28.  
    29. Connect the positive (+) battery cable and then the negative (-) battery cable.
    30.  
    31. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    32.  

    Range Rover (2001-02)



    1. Disconnect the negative (-) battery cable; then the positive (+) battery cable.
    2.  


    NOTE
    Wait at least 20 minutes for the air bag(s) to discharge before performing any work on the system(s).

    1. If equipped with SRS, remove the battery.
    2.  
    3. Drain the cooling system into a clean container for reuse.
    4.  
    5. Loosen the hose clips and disconnect the heater hoses from the heater tubes.
    6.  
    7. If equipped with air conditioning, perform the following procedure:
      1. Discharge and recover the air conditioning refrigerant.
      2.  
      3. Remove the refrigerant pipes mount-to-evaporator bolt
      4.  
      5. Disconnect the pipes and discard the O-rings.
      6.  
      7. Plug the openings to prevent contamination.
      8.  

    8.  
    9. Remove the dash panel assembly by performing the following procedures:
      1. Remove the center console.
      2.  
      3. Remove the wiper motor and linkage.
      4.  
      5. Remove the steering column.
      6.  
      7. At the passenger-s side, remove the clip and disconnect the heated front screen multiplug connector.
      8.  
      9. Remove the 6 scuttle side panel-to-chassis bolts and the side panel.
      10.  
      11. Remove the heater intake pollen filters.
      12.  
      13. Remove the 8 pollen filter housing screws from each housing and remove both housings.
      14.  
      15. Remove the radio.
      16.  
      17. Near the A-post lower trim panels, remove the door aperture seal.
      18.  
      19. If equipped with a footrest on the driver-s side, remove the 3 foot rest-to-A-post lower trim bolts and remove the foot rest.
      20.  
      21. At each A-post-s lower trim panel, remove the screw and release the spring clip and remove both trim panels.
      22.  
      23. At the driver-s seat base trim, remove the fuse cover.
      24.  
      25. Remove the screw, the 2 trim studs and the seat base trim.
      26.  
      27. At the driver-s side, release the 4 spring clips and remove the carpet retainer.
      28.  
      29. Remove the 2 lower closing panel-to-passenger side scrivet fasteners and the panel.
      30.  
      31. Release the closing panel, disconnect the footwell lamp and the diagnostic multiplug connector; then, remove the closing panel.
      32.  
      33. Remove the 4 dash center bracket bolts and the bracket.
      34.  
      35. Disconnect the 4 multiplug connectors from the Body Control Module (BCM).
      36.  
      37. At the base of the A-post on the driver-s side, remove the ground wires from the stud.
      38.  
      39. Disconnect the multiplug electrical connectors at the base of each A-post.
      40.  
      41. Disconnect the BCM electrical harness from the sill and move it into the dash panel so it will not hamper removal of the dash panel.
      42.  
      43. At the brake and clutch switches, disconnect the multiplug electrical connectors and vacuum hose.
      44.  
      45. If equipped with SRS, disconnect the following items:
      46.  

      1. The SRS harness connector from the main wiring harness
      2.  
      3. The SRS harness connector from the control module
      4.  
      5. Remove both front wheel arch liners.
      6.  
      7. At the left wheel arch, remove the 2 air cleaner baffle scrivet fasteners and the baffle.
      8.  
      9. If equipped with SRS, disconnect both SRS crash sensor electrical connectors.
      10.  
      11. Remove the 4 battery tray bolts and the 2 air cleaner-to-valance bolts.
      12.  
      13. Raise the air cleaner and battery tray to access the crash sensor harness clips.
      14.  
      15. Disconnect the crash sensor harness-to-valance clips; then, move the harnesses into the wheel arches.
      16.  
      17. Disconnect the 3 crash sensor harness-to-underside wheel arches; then, move the harness through the bulkhead and into the dash.
      18.  
      19. At the top of the dash panel, remove the 4 dash panel-to-scuttle panel tube bolts.
      20.  
      21. Remove the dash panel-to-chassis bolts. Pull the panel rearward and support it on 50mm deep wooden blocks.
      22.  

    10.  
    11. With the dash panel supported on 50mm deep wooden blocks, remove the face level vent ducts-to-dash screws; there is a vent duct located on both sides of the dash.
    12.  
    13. Remove the face level vent ducts inserts from the heater unit.
    14.  
    15. Remove the passenger-s side blower duct.
    16.  
    17. Remove the 4 heater control panel-to-dash panel screws and remove the panel.
    18.  
    19. Disconnect the 4 multiplug connectors from the heater control panel and remove the control panel.
    20.  
    21. Remove the 5 center switch assembly-to-dash screws and remove the center switch assembly.
    22.  
    23. Disconnect the multiplug connectors from the solar sensor and the alarm LED; then push the leads into the dash ducting.
    24.  
    25. Disconnect the harness-to-dash ducting clip; then, position the solar sensor/LED harness aside.
    26.  
    27. Disconnect the water temperature sensor-to-heater core inlet pipe clip and position the sensor aside.
    28.  
    29. Disconnect the multiplug connector from the evaporator sensor.
    30.  
    31. Disconnect the 2 harness-to-heater base clips.
    32.  
    33. Remove the 4 heater housing-to-dash frame bolts.
    34.  
    35. Using an assistant, hold the harness away and remove the heater housing.
    36.  
    37. Remove the right side duct-to-heater/air conditioning housing screws and the duct.
    38.  
    39. Remove the heater pipe bracket screw.
    40.  
    41. Remove the 2 right side servo-to-heater/air conditioning housing screws and the servo.
    42.  
    43. Remove the heater core/pipe assembly-to-heater/air conditioning housing clips and the heater core/pipe assembly.
    44.  
    45. If installing a new heater core, remove the 2 heater core-to-heater pipe assembly screws and separate the heater pipe assembly. Discard the O-rings.
    46.  


      Click image to see an enlarged view

      Fig. View of the center switch assembly-Range Rover (2001-02)


    To install:

    1. If installing a new heater core, install new O-rings, the heater pipe assembly and the 2 heater core-to-heater pipe assembly screws.
    2.  
    3. Install the heater core/pipe assembly and the heater core/pipe assembly-to-heater/air conditioning housing clips.
    4.  
    5. Install the right side servo and the 2 servo-to-heater/air conditioning housing screws.
    6.  
    7. Install the heater pipe bracket screw.
    8.  
    9. Install the right side duct and the duct-to-heater/air conditioning housing screws.
    10.  
    11. Using an assistant, install the heater housing.
    12.  
    13. Install the 4 heater housing-to-dash frame bolts.
    14.  
    15. Connect the 2 harness-to-heater base clips.
    16.  
    17. Connect the multiplug connector to the evaporator sensor.
    18.  
    19. Connect the water temperature sensor-to-heater core inlet pipe clip.
    20.  
    21. Connect the harness-to-dash ducting clip.
    22.  
    23. Connect the multiplug connectors to the solar sensor and the alarm LED.
    24.  
    25. Install the center switch assembly and the 5 center switch assembly-to-dash screws.
    26.  
    27. Install the control panel and connect the 4 multiplug connectors to the heater control panel.
    28.  
    29. Install the heater control panel and the 4 panel-to-dash panel screws.
    30.  
    31. Install the passenger-s side blower duct.
    32.  
    33. Install the face level vent ducts inserts to the heater unit.
    34.  
    35. With the dash panel supported on 50mm deep wooden blocks, install the face level vent ducts-to-dash screws; there is a vent duct located on both sides of the dash.
    36.  
    37. Install the dash panel assembly by performing the following procedures:

      Push the panel forward and support it on 50mm deep wooden blocks. Install the dash panel-to-chassis bolts.
       
      At the top of the dash panel, install the 4 dash panel-to-scuttle panel tube bolts.
       
      Connect the 3 crash sensor harness-to-underside wheel arches.
       
      Connect the crash sensor harness-to-valance clips.
       
      Install the 4 battery tray bolts and the 2 air cleaner-to-valance bolts.
       
      If equipped with SRS, connect both SRS crash sensor electrical connectors.
       
      At the left wheel arch, install the air cleaner baffle and the 2 baffle scrivet fasteners.
       
      Install both front wheel arch liners.
       
      If equipped with SRS, connect the following items:
       

      1. The SRS harness connector to the main wiring harness
      2.  
      3. The SRS harness connector to the control module
      4.  
      5. At the brake and clutch switches, connect the multiplug electrical connectors and vacuum hose.
      6.  
      7. Connect the BCM electrical harness to the sill.
      8.  
      9. Connect the multiplug electrical connectors at the base of each A-post.
      10.  
      11. At the base of the A-post on the driver-s side, install the ground wires to the stud.
      12.  
      13. Connect the 4 multiplug connectors to the Body Control Module (BCM).
      14.  
      15. Install the dash center bracket and the 4 bracket bolts.
      16.  
      17. Install the closing panel; then, connect the footwell lamp and the diagnostic multiplug connector.
      18.  
      19. Install the lower closing panel and the 2 panel-to-passenger side scrivet fasteners.
      20.  
      21. At the driver-s side, install the carpet retainer and the 4 spring clips.
      22.  
      23. Install the seat base trim, the 2 trim studs and the screw.
      24.  
      25. At the driver-s seat base trim, install the fuse cover.
      26.  
      27. At each A-post-s lower trim panel, install both trim panels, the screw and the spring clip.
      28.  
      29. If equipped with a foot rest on the driver-s side, install the foot rest and the 3 foot rest-to-A-post lower trim bolts.
      30.  
      31. Near the A-post lower trim panels, install the door aperture seal.
      32.  
      33. Install the radio.
      34.  
      35. Install the both pollen filter housings and the 8 housing screws to each housing.
      36.  
      37. Install the heater intake pollen filters.
      38.  
      39. Install the scuttle side panel and the 6 side panel-to-chassis bolts.
      40.  
      41. At the passenger-s side, connect the heated front screen multiplug connector and install the clip.
      42.  
      43. Install the steering column.
      44.  
      45. Install the wiper motor and linkage.
      46.  
      47. Install the center console.
      48.  

    38.  
    39. If equipped with air conditioning, perform the following procedure:
      1. Lubricate and install new O-rings and connect the pipes.
      2.  
      3. Install the refrigerant pipes mount-to-evaporator bolt.
      4.  

    40.  
    41. Connect the heater hoses to the heater tubes and install the hose clips.
    42.  
    43. Refill the cooling system.
    44.  
    45. If the battery was removed, install it.
    46.  
    47. Connect the positive (+) battery cable; then, the negative (-) battery cable.
    48.  
    49. Evacuate and charge the air conditioning system.
    50.  
    51. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    52.  

    Range Rover (2003-04)



    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Disconnect the negative (-) battery cable; then the positive (+) battery cable.
    4.  


    NOTE
    Wait at least 20 minutes for the air bag(s) to discharge before performing any work on the system(s).


    NOTE
    The instrument panel fascia is released from the passenger side and swung out for access with the main harness still attached.



    Drain the cooling system into a clean container for reuse.
     
    Discharge and recover the air conditioning refrigerant.
     
    Remove the air intake plenum.
     
    Release the driver side air bag by inserting a 2 inch (50 mm) rod through the steering wheel access hole on each side and push on the rod until the air bag clips are released.
     
    Disconnect the electrical connectors and remove air bag.
     
    With the front wheels in the straight ahead position, note the position of the steering wheel to column alignment marks, then remove the steering wheel.
     
    Remove the passenger side air bag.
     
    Remove the front seat belt anchor bolts.
     
    Remove the front seats.
     
    Remove the center console footwell panels.
     
    Remove the driver side upper finish panel.
     
    Remove the passenger side lower finish panel.
     
    Remove 7 screws attaching the glove box.
     
    Disconnect lamp connector, glove box latch cable and 2 screws attaching CD player to glove box.
     
    Remove CD player and glove box assembly.
     
    Remove center console finish panel.
     
    Remove center console side panels.
     
    Remove storage box from center console, along with 2 screws and washer at base of storage box opening.
     
    Remove 2 screws attaching ignition switch to center console.
     
    Remove 1 screw attaching center console to instrument panel.
     
    Remove center console rear closing panel.
     
    Raise the rear of the center console and disconnect 3 electrical connectors and air duct.
     
    Remove 3 connectors from the accessory power socket and then remove center console.
     
    Release 4 clips attaching the heater control panel, and remove the control panel.
     
    Remove the air suspension control panel, located below the heater control panel.
     
    Remove the handbrake lever assembly.
     
    Remove the air ducts from the heater-A/C assembly.
     
    Remove the driver-s foot rest.
     
    Remove the upper and lower A pillar finish panels.
     
    Remove instrument panel side fascia from both sides.
     
    Remove the gearshift selector assembly.
     
    Remove 4 nuts attaching the gearshift selector assembly carrier and remove the carrier.
     


    NOTE
    Cover the selector assembly mounting studs to prevent damage to the instrument panel.

    1. Remove 4 bolts attaching the handbrake mounting bracket and remove the bracket.
    2.  
    3. Remove 4 bolts attaching the center console mounting bracket and remove the bracket.
    4.  
    5. Mark the location of the steering column lower shaft to the intermediate shaft, then remove the clamp securing them together.
    6.  
    7. Remove 2 nuts attaching steering support bearing to the body, release the bearing and disconnect the shaft.
    8.  
    9. Remove the wiper arm, disconnect the wiper motor and position aside.
    10.  
    11. From inside the engine compartment, remove 2 bolts attaching the instrument panel to the firewall.
    12.  
    13. Disconnect the A/C lines from the firewall, discard the o-rings and cap the line openings.
    14.  
    15. Disconnect the heater hoses at the firewall.
    16.  
    17. Remove 3 nuts attaching the heater assembly to the firewall.
    18.  
    19. From inside the vehicle, remove 4 nuts and 2 bolts attaching the instrument panel to the body.
    20.  
    21. Disconnect electrical connectors and release wiring harnesses from both A pillars.
    22.  
    23. Pull out instrument panel enough to disconnect airbag connectors.
    24.  
    25. Remove the transfer case Electronic Control Unit (ECU).
    26.  
    27. From inside the engine compartment, disconnect the power lead, relay and connector from firewall fuse box.
    28.  
    29. Disconnect headlight check control module from A pillar and position aside.
    30.  
    31. Remove door harness connector block from A pillar.
    32.  
    33. Remove ground header from A pillar.
    34.  
    35. Raise carpet and remove 3 bolts attaching wiring harness cover panel and remove panel.
    36.  
    37. Disconnect wiring harness connector block from Body Control Unit (BCU) carrier.
    38.  
    39. Remove 2 nuts and position BCU carrier aside.
    40.  
    41. Release the main wiring harness from the channel and withdraw the harness through the firewall.
    42.  
    43. With the aid of an assistant, rotate the instrument panel outward and support it on suitable stands to protect trim and carpet.
    44.  
    45. Disconnect air blend motor connector and remove motor.
    46.  
    47. Disconnect screws and nut from rear of instrument panel tray and release clip to allow wiring harness to move.
    48.  
    49. Remove 2 nuts attaching HVAC assembly.
    50.  
    51. With an assistant, remove the HVAC assembly from vehicle.
    52.  
    53. Turn HVAC assembly upside down and remove left side heat duct.
    54.  
    55. Remove heater pipes from assembly and discard o-rings.
    56.  
    57. Remove right side heat duct.
    58.  
    59. Disconnect all electrical connectors.
    60.  
    61. Remove rear air vent motor.
    62.  
    63. Remove thermal expansion valve cover.
    64.  
    65. Remove 7 screws and 3 clips from lower HVAC access panel and remove panel.
    66.  
    67. Remove heater core from HVAC assembly.
    68.  


      Click image to see an enlarged view

      Fig. Instrument panel mounting-Range Rover (2003-04)



      Click image to see an enlarged view

      Fig. Rear of instrument panel wiring harness mounting-Range Rover (2003-04)



      Click image to see an enlarged view

      Fig. HVAC assembly mounting bolts-Range Rover (2003-04)



      Click image to see an enlarged view

      Fig. Removing HVAC lower access panel-Range Rover (2003-04)


    To install:

    1. Install heater core to HVAC assembly.
    2.  
    3. Install lower access panel.
    4.  
    5. Install thermal expansion valve cover.
    6.  
    7. Install rear air vent motor.
    8.  
    9. Connect all electrical connectors.
    10.  
    11. Install right side heat duct
    12.  
    13. Install heater pipes to HVAC assembly using NEW o-rings
    14.  
    15. Install left side heat duct.
    16.  
    17. With an assistant, install the HVAC assembly into the vehicle and tighten the nuts.
    18.  
    19. Place wiring harness into position in rear of instrument panel tray and clips and screws.
    20.  
    21. Connect air blend motor connector and install motor.
    22.  
    23. With the aid of an assistant, rotate the instrument panel inward and place it in position.
    24.  
    25. Feed the main wiring harness through the firewall.
    26.  
    27. Raise carpet and place the main harness in the channel and install wiring harness cover panel.
    28.  
    29. Install the BCU carrier.
    30.  
    31. Connect wiring harness connector block to BCU carrier.
    32.  
    33. Install ground header to A pillar.
    34.  
    35. Install door harness connector block to A pillar.
    36.  
    37. Install headlight check control module to A pillar.
    38.  
    39. From inside the engine compartment, install the power lead, relay and connector to firewall fuse box.
    40.  
    41. Install the transfer case Electronic Control Unit (ECU).
    42.  
    43. Pull out instrument panel enough to reconnect airbag connectors.
    44.  
    45. Connect electrical connectors and attach wiring harnesses to both A pillars.
    46.  
    47. From inside the vehicle, install 4 nuts and 2 bolts attaching the instrument panel to the body. Tighten the fasteners to 18 ft. lbs. (25 Nm).
    48.  
    49. Install 3 nuts attaching the heater assembly to the firewall and tighten to 7 ft. lbs. (10 Nm).
    50.  
    51. Connect the heater hoses at the firewall.
    52.  
    53. Connect the A/C lines to the firewall, using NEW the o-rings.
    54.  
    55. From inside the engine compartment, install 2 bolts attaching the instrument panel to the firewall. Tighten the bolts to 18 ft. lbs. (25 Nm).
    56.  
    57. Install the wiper motor and tighten to 7 ft. lbs. (10 Nm).
    58.  
    59. Install the wiper arm and tighten to 18 ft. lbs. (25 Nm).
    60.  
    61. Install 2 nuts attaching steering support bearing to the body, and tighten to 18 ft. lbs. (25 Nm).
    62.  
    63. Using marks made on removal, position the steering column lower shaft to the intermediate shaft, and tighten the bolt to 18 ft. lbs. (25 Nm).
    64.  
    65. Install 4 bolts attaching the center console mounting bracket and tighten to 7 ft. lbs. (10 Nm).
    66.  
    67. Install 4 bolts attaching the handbrake mounting bracket and tighten to 18 ft. lbs. (25 Nm).
    68.  
    69. Install 4 nuts attaching the gearshift selector assembly carrier and tighten to 18 ft. lbs. (25 Nm).
    70.  
    71. Install the gearshift selector assembly.
    72.  
    73. Install instrument panel side fascia to both sides.
    74.  
    75. Install the upper and lower A pillar finish panels.
    76.  
    77. Install the driver-s foot rest.
    78.  
    79. Install the air ducts to the heater-A/C assembly.
    80.  
    81. Install the handbrake lever assembly.
    82.  
    83. Install the air suspension control panel.
    84.  
    85. Install the heater control panel.
    86.  
    87. Install the center console.
    88.  
    89. Connect 3 connectors to accessory power socket.
    90.  
    91. Raise the rear of the center console and connect 3 electrical connectors and air duct.
    92.  
    93. Install center console rear closing panel.
    94.  
    95. Install 1 screw attaching center console to instrument panel.
    96.  
    97. Install 2 screws attaching ignition switch to center console.
    98.  
    99. Install 2 screws and washer at base of storage box opening.
    100.  
    101. Install storage box.
    102.  
    103. Install center console side panels.
    104.  
    105. Install center console finish panel.
    106.  
    107. Install CD player and glove box assembly.
    108.  
    109. Install the passenger side lower finish panel.
    110.  
    111. Install the driver side upper finish panel.
    112.  
    113. Install the center console footwell panels.
    114.  
    115. Install the front seats and tighten the bolts to 33 ft. lbs. (45 Nm).
    116.  
    117. Install the seal belt anchor bolts and tighten to 35 ft. lbs. (48 Nm).
    118.  
    119. Install the passenger side air bag and tighten the bolts to 16 ft. lbs. (22 Nm).
    120.  
    121. Noting the position of the steering wheel to column alignment marks, install the steering wheel and tighten the bolt to 46 ft. lbs. (63 Nm).
    122.  
    123. Release the driver side air bag by inserting a 2 inch (50 mm) rod through the steering wheel access hole on each side and push on the rod until the air bag clips are released.
    124.  
    125. Connect the electrical connectors and install driver side air bag. Tighten the screws to 22 inch lbs. (2.5 Nm).
    126.  
    127. Install the air intake plenum.
    128.  
    129. Charge the air conditioning refrigerant.
    130.  
    131. Fill the cooling system.
    132.  
    133. Connect the battery cables.
    134.  
    135. Start the vehicle and check for leaks and proper heater operation.
    136.  

    Discovery



    1. Turn the steering wheel 90° from horizontal.
    2.  
    3. Turn the ignition switch OFF.
    4.  
    5. Disconnect the negative (() battery cable and then the positive (+) battery cable.
      NOTE
      Wait at least 20 minutes for the air bag(s) to discharge before performing any work on the system(s).

    6.  
    7. Drain the cooling system into a clean container for reuse.
    8.  
    9. Discharge and recover the air conditioning system refrigerant.
    10.  
    11. Remove the dash panel assembly by performing the following procedure:
      1. Move the seats rearward.
      2.  
      3. Working under the dash panel assembly, disconnect the air bag multi-plug electrical connectors.
      4.  
      5. Remove the glove box.
      6.  
      7. Remove the center console assembly.
      8.  
      9. Remove the driver-s SRS module, by disconnecting or removing following items:
        CAUTION
        Do not allow the air bag module to hang by electrical harness.



        Under the steering wheel, release the lower dash panel cover turnbuckles and remove the lower dash panel.
         
        Disconnect the air bag harness connector from the yellow air bag column harness.
         
        Using a special socket, remove the 2 tamper-proof resistor air bag module-to-steering wheel screws.
         
        Remove the air bag module from the steering wheel.
         



        Disconnect the air bag harness connector.
         
        Remove the air bag module.
         

      10.  
      11. Remove the passenger-s SRS module, by disconnecting or removing following items:
        CAUTION
        Do not allow the air bag module to hang by electrical harness.



        Open the glove box door and disconnect the air bag module electrical connector.
         
        Using a special socket and a long extension, remove both front air bag module-to-dash panel screws.
         
        Using a Torx® socket, remove both rear air bag module-to-dash panel screws.
         
        Remove the air bag module from the dash panel.
         



        Disconnect the air bag harness connector.
         

      12.  
      13. Release the clamp and lower the steering column.
      14.  
      15. Remove the steering wheel and the steering column switch.
      16.  
      17. Remove the instrument housing.
      18.  
      19. Disconnect the electrical connectors and remove the radio.
      20.  
      21. Remove the exterior mirrors switch panel and the coin tray.
      22.  
      23. Remove the switch panel and the clock.
      24.  
      25. Remove the passenger-s side relay assembly mounting bracket screw and move the assembly aside.
      26.  
      27. Turn the heater controls fully clockwise. Noting the position of the levers, disconnect the heater control cables from the levers and outer cable from the retaining clips.
      28.  
      29. Remove the 4 dash panel-to-center lower mounting bracket bolts.
      30.  
      31. Remove the 4 dash panel-to-side lower mounting bracket bolts.
      32.  
      33. Working below the steering column, remove the 4 driver-s knee bolster pads screws and both knee bolster pads.
      34.  
      35. Remove the 4 instrument bracket-to-dash panel nuts.
      36.  
      37. Using an assistant, partially maneuver the dash panel rearward.
      38.  
      39. At the driver-s side, disconnect the 6 dash harness-to-main harness multi-plugs connectors.
      40.  
      41. Disconnect the 3 dash harness-to-fusebox multi-plug connectors.
      42.  
      43. Using an assistant, remove the dash panel assembly from the vehicle.
      44.  

    12.  
    13. In the engine compartment, disconnect the heater hoses from the heater tubes.
    14.  
    15. Release the P-clip securing both the high and low air conditioning pressure tubes.
    16.  
    17. Remove both the high and low pressure tubes-to-evaporator bolts; then, separate the tubes from the evaporator and discard the O-rings.
    18.  
    19. At the lower right side of the heater/air conditioning housing, disconnect the heater-to-blower motor multi-plug connector.
    20.  
    21. Remove the 3 blower motor housing screws and remove the blower motor housing.
    22.  
    23. Remove the 5 heater/air conditioning housing-to-chassis screws.
    24.  
    25. Remove the 2 center console front mounting bracket-to-chassis bolts and remove the center console front mounting bracket.
    26.  
    27. Disconnect both drain tubes.
    28.  
    29. Carefully, remove the heater/air conditioning housing from the vehicle.
    30.  
    31. Remove both right side footwell outlet-to-heater/air conditioning housing screws and the outlet.
    32.  
    33. Remove the heater hoses-to-heater assembly clip.
    34.  
    35. Slide the heater core from the heater/air conditioning housing.

      Click image to see an enlarged view

      Fig. View of the steering wheel, SRS module and special tool-Land Rover Discovery



      Click image to see an enlarged view

      Fig. View of the passenger-s side SRS module and special screws-Land Rover Discovery



      Click image to see an enlarged view

      Fig. View of the heater/air conditioning housing assembly-Land Rover Discovery



      Click image to see an enlarged view

      Fig. View of the heater core and related components-Land Rover Discovery

    36.  

    To install:

    1. If installing a new heater core, transfer the heater hoses to the new heater core.
    2.  
    3. Slide the heater core into the heater/air conditioning housing.
    4.  
    5. Install the heater hoses-to-heater assembly clip.
    6.  
    7. Install the right side footwell outlet and both outlet-to-heater/air conditioning housing screws.
    8.  
    9. Carefully, install the heater/air conditioning housing to the vehicle.
    10.  
    11. Connect both drain tubes.
    12.  
    13. Install the center console front mounting bracket and the 2 center console front mounting bracket-to-chassis bolts.
    14.  
    15. Install the 5 heater/air conditioning housing-to-chassis screws.
    16.  
    17. Install the blower motor housing and the 3 blower motor housing screws.
    18.  
    19. At the lower right side of the heater/air conditioning housing, connect the heater-to-blower motor multi-plug connector.
    20.  
    21. Using new O-rings, assemble the tubes to the evaporator and install both the high and low pressure tubes-to-evaporator bolts.
    22.  
    23. Install the P-clip securing both the high and low air conditioning pressure tubes.
    24.  
    25. In the engine compartment, connect the heater hoses to the heater tubes.
    26.  
    27. Install the dash panel assembly by performing the following procedure:
      1. Using an assistant, install the dash panel assembly to the vehicle.
      2.  
      3. Connect the 3 dash harness-to-fuse box multi-plug connectors.
      4.  
      5. At the driver-s side, connect the 6 dash harness-to-main harness multi-plugs connectors.
      6.  
      7. Using an assistant, partially maneuver the dash panel forward.
      8.  
      9. Install the 4 instrument bracket-to-dash panel nuts.
      10.  
      11. Working below the steering column, install both knee bolster pads and the 4 driver-s knee bolster pads screws.
      12.  
      13. Install the 4 dash panel-to-side lower mounting bracket bolts.
      14.  
      15. Install the 4 dash panel-to-center lower mounting bracket bolts.
      16.  
      17. Noting the position of the levers, connect the heater control cables to the levers and outer cable to the retaining clips.
      18.  
      19. Install the passenger-s side relay assembly mounting bracket and the assembly screw.
      20.  
      21. Install the switch panel and the clock.
      22.  
      23. Install the exterior mirrors switch panel and the coin tray.
      24.  
      25. Connect the electrical connectors and install the radio.
      26.  
      27. Install the instrument housing.
      28.  
      29. Install the steering column switch and the steering wheel.
      30.  
      31. Raise the steering column and install the clamp.
      32.  
      33. Install the passenger-s SRS module, by connecting or installing following items:

        Connect the air bag harness connector.
         
        Install the air bag module to the dash panel.
         
        Using a Torx® socket, install both rear air bag module-to-dash panel screws.
         
        Using a special socket and a long extension, install both front air bag module-to-dash panel screws.
         
        Open the glove box door and connect the air bag module electrical connector.
         

      34.  
      35. Install the driver-s SRS module, by connecting or installing following items:

        Install the air bag module.
         
        Connect the air bag harness connector.
         
        Install the air bag module to the steering wheel.
         
        Using a special socket, install the 2 tamper-proof resistor air bag module-to-steering wheel screws.
         
        Connect the air bag harness connector to the yellow air bag column harness.
         
        Under the steering wheel, install the lower dash panel and install the lower dash panel cover turnbuckles.
         

      36.  
      37. Install the center console assembly.
      38.  
      39. Install the glove box.
      40.  
      41. Working under the dash panel assembly, connect the air bag multi-plug electrical connectors.
      42.  
      43. Move the seats forward.
      44.  

    28.  
    29. Refill the cooling system.
    30.  
    31. Connect the positive (+) battery cable and then the negative (() battery cable.
    32.  
    33. Evacuate and charge the air conditioning system.
    34.  
    35. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    36.  

    1. Turn the steering wheel 90° from horizontal.
    2.  
    3. Turn the ignition switch OFF.
    4.  
    5. Disconnect the negative (() battery cable and then the positive (+) battery cable.
      NOTE
      Wait at least 20 minutes for the air bag(s) to discharge before performing any work on the system(s).

    6.  
    7. Drain the cooling system into a clean container for reuse.
    8.  
    9. Discharge and recover the air conditioning system refrigerant.
    10.  
    11. Remove the dash panel assembly by performing the following procedure:
      1. Move the seats rearward.
      2.  
      3. Working under the dash panel assembly, disconnect the air bag multi-plug electrical connectors.
      4.  
      5. Remove the glove box.
      6.  
      7. Remove the center console assembly.
      8.  
      9. Remove the driver-s SRS module, by disconnecting or removing following items:
        CAUTION
        Do not allow the air bag module to hang by electrical harness.



        Under the steering wheel, release the lower dash panel cover turnbuckles and remove the lower dash panel.
         
        Disconnect the air bag harness connector from the yellow air bag column harness.
         
        Using a special socket, remove the 2 tamper-proof resistor air bag module-to-steering wheel screws.
         
        Remove the air bag module from the steering wheel.
         



        Disconnect the air bag harness connector.
         
        Remove the air bag module.
         

      10.  
      11. Remove the passenger-s SRS module, by disconnecting or removing following items:
        CAUTION
        Do not allow the air bag module to hang by electrical harness.



        Open the glove box door and disconnect the air bag module electrical connector.
         
        Using a special socket and a long extension, remove both front air bag module-to-dash panel screws.
         
        Using a Torx® socket, remove both rear air bag module-to-dash panel screws.
         
        Remove the air bag module from the dash panel.
         



        Disconnect the air bag harness connector.
         

      12.  
      13. Release the clamp and lower the steering column.
      14.  
      15. Remove the steering wheel and the steering column switch.
      16.  
      17. Remove the instrument housing.
      18.  
      19. Disconnect the electrical connectors and remove the radio.
      20.  
      21. Remove the exterior mirrors switch panel and the coin tray.
      22.  
      23. Remove the switch panel and the clock.
      24.  
      25. Remove the passenger-s side relay assembly mounting bracket screw and move the assembly aside.
      26.  
      27. Turn the heater controls fully clockwise. Noting the position of the levers, disconnect the heater control cables from the levers and outer cable from the retaining clips.
      28.  
      29. Remove the 4 dash panel-to-center lower mounting bracket bolts.
      30.  
      31. Remove the 4 dash panel-to-side lower mounting bracket bolts.
      32.  
      33. Working below the steering column, remove the 4 driver-s knee bolster pads screws and both knee bolster pads.
      34.  
      35. Remove the 4 instrument bracket-to-dash panel nuts.
      36.  
      37. Using an assistant, partially maneuver the dash panel rearward.
      38.  
      39. At the driver-s side, disconnect the 6 dash harness-to-main harness multi-plugs connectors.
      40.  
      41. Disconnect the 3 dash harness-to-fusebox multi-plug connectors.
      42.  
      43. Using an assistant, remove the dash panel assembly from the vehicle.
      44.  

    12.  
    13. In the engine compartment, disconnect the heater hoses from the heater tubes.
    14.  
    15. Release the P-clip securing both the high and low air conditioning pressure tubes.
    16.  
    17. Remove both the high and low pressure tubes-to-evaporator bolts; then, separate the tubes from the evaporator and discard the O-rings.
    18.  
    19. At the lower right side of the heater/air conditioning housing, disconnect the heater-to-blower motor multi-plug connector.
    20.  
    21. Remove the 3 blower motor housing screws and remove the blower motor housing.
    22.  
    23. Remove the 5 heater/air conditioning housing-to-chassis screws.
    24.  
    25. Remove the 2 center console front mounting bracket-to-chassis bolts and remove the center console front mounting bracket.
    26.  
    27. Disconnect both drain tubes.
    28.  
    29. Carefully, remove the heater/air conditioning housing from the vehicle.
    30.  
    31. Remove both right side footwell outlet-to-heater/air conditioning housing screws and the outlet.
    32.  
    33. Remove the heater hoses-to-heater assembly clip.
    34.  
    35. Slide the heater core from the heater/air conditioning housing.

      Click image to see an enlarged view

      Fig. View of the steering wheel, SRS module and special tool-Land Rover Discovery



      Click image to see an enlarged view

      Fig. View of the passenger-s side SRS module and special screws-Land Rover Discovery



      Click image to see an enlarged view

      Fig. View of the heater/air conditioning housing assembly-Land Rover Discovery



      Click image to see an enlarged view

      Fig. View of the heater core and related components-Land Rover Discovery

    36.  

    To install:

    1. If installing a new heater core, transfer the heater hoses to the new heater core.
    2.  
    3. Slide the heater core into the heater/air conditioning housing.
    4.  
    5. Install the heater hoses-to-heater assembly clip.
    6.  
    7. Install the right side footwell outlet and both outlet-to-heater/air conditioning housing screws.
    8.  
    9. Carefully, install the heater/air conditioning housing to the vehicle.
    10.  
    11. Connect both drain tubes.
    12.  
    13. Install the center console front mounting bracket and the 2 center console front mounting bracket-to-chassis bolts.
    14.  
    15. Install the 5 heater/air conditioning housing-to-chassis screws.
    16.  
    17. Install the blower motor housing and the 3 blower motor housing screws.
    18.  
    19. At the lower right side of the heater/air conditioning housing, connect the heater-to-blower motor multi-plug connector.
    20.  
    21. Using new O-rings, assemble the tubes to the evaporator and install both the high and low pressure tubes-to-evaporator bolts.
    22.  
    23. Install the P-clip securing both the high and low air conditioning pressure tubes.
    24.  
    25. In the engine compartment, connect the heater hoses to the heater tubes.
    26.  
    27. Install the dash panel assembly by performing the following procedure:
      1. Using an assistant, install the dash panel assembly to the vehicle.
      2.  
      3. Connect the 3 dash harness-to-fuse box multi-plug connectors.
      4.  
      5. At the driver-s side, connect the 6 dash harness-to-main harness multi-plugs connectors.
      6.  
      7. Using an assistant, partially maneuver the dash panel forward.
      8.  
      9. Install the 4 instrument bracket-to-dash panel nuts.
      10.  
      11. Working below the steering column, install both knee bolster pads and the 4 driver-s knee bolster pads screws.
      12.  
      13. Install the 4 dash panel-to-side lower mounting bracket bolts.
      14.  
      15. Install the 4 dash panel-to-center lower mounting bracket bolts.
      16.  
      17. Noting the position of the levers, connect the heater control cables to the levers and outer cable to the retaining clips.
      18.  
      19. Install the passenger-s side relay assembly mounting bracket and the assembly screw.
      20.  
      21. Install the switch panel and the clock.
      22.  
      23. Install the exterior mirrors switch panel and the coin tray.
      24.  
      25. Connect the electrical connectors and install the radio.
      26.  
      27. Install the instrument housing.
      28.  
      29. Install the steering column switch and the steering wheel.
      30.  
      31. Raise the steering column and install the clamp.
      32.  
      33. Install the passenger-s SRS module, by connecting or installing following items:

        Connect the air bag harness connector.
         
        Install the air bag module to the dash panel.
         
        Using a Torx® socket, install both rear air bag module-to-dash panel screws.
         
        Using a special socket and a long extension, install both front air bag module-to-dash panel screws.
         
        Open the glove box door and connect the air bag module electrical connector.
         

      34.  
      35. Install the driver-s SRS module, by connecting or installing following items:

        Install the air bag module.
         
        Connect the air bag harness connector.
         
        Install the air bag module to the steering wheel.
         
        Using a special socket, install the 2 tamper-proof resistor air bag module-to-steering wheel screws.
         
        Connect the air bag harness connector to the yellow air bag column harness.
         
        Under the steering wheel, install the lower dash panel and install the lower dash panel cover turnbuckles.
         

      36.  
      37. Install the center console assembly.
      38.  
      39. Install the glove box.
      40.  
      41. Working under the dash panel assembly, connect the air bag multi-plug electrical connectors.
      42.  
      43. Move the seats forward.
      44.  

    28.  
    29. Refill the cooling system.
    30.  
    31. Connect the positive (+) battery cable and then the negative (() battery cable.
    32.  
    33. Evacuate and charge the air conditioning system.
    34.  
    35. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    36.  

    Range Rover



    1. Disconnect the negative (() battery cable; then the positive (+) battery cable.
      NOTE
      Wait at least 20 minutes for the air bag(s) to discharge before performing any work on the system(s).

    2.  
    3. If equipped with SRS, remove the battery.
    4.  
    5. Drain the cooling system into a clean container for reuse.
    6.  
    7. Loosen the hose clips and disconnect the heater hoses from the heater tubes.
    8.  
    9. If equipped with air conditioning, perform the following procedure:
      1. Discharge and recover the air conditioning refrigerant.
      2.  
      3. Remove the refrigerant pipes mount-to-evaporator bolt
      4.  
      5. Disconnect the pipes and discard the O-rings.
      6.  
      7. Plug the openings to prevent contamination.
      8.  

    10.  
    11. Remove the dash panel assembly by performing the following procedures:
      1. Remove the center console.
      2.  
      3. Remove the wiper motor and linkage.
      4.  
      5. Remove the steering column.
      6.  
      7. At the passenger-s side, remove the clip and disconnect the heated front screen multi-plug connector.
      8.  
      9. Remove the 6 scuttle side panel-to-chassis bolts and the side panel.
      10.  
      11. Remove the heater intake pollen filters.
      12.  
      13. Remove the 8 pollen filter housing screws from each housing and remove both housings.
      14.  
      15. Remove the radio.
      16.  
      17. Near the A-post lower trim panels, remove the door aperture seal.
      18.  
      19. If equipped with a footrest on the driver-s side, remove the 3 foot rest-to-A-post lower trim bolts and remove the foot rest.
      20.  
      21. At each A-post-s lower trim panel, remove the screw and release the spring clip and remove both trim panels.
      22.  
      23. At the driver-s seat base trim, remove the fuse cover.
      24.  
      25. Remove the screw, the 2 trim studs and the seat base trim.
      26.  
      27. At the driver-s side, release the 4 spring clips and remove the carpet retainer.
      28.  
      29. Remove the 2 lower closing panel-to-passenger side scrivet fasteners and the panel.
      30.  
      31. Release the closing panel, disconnect the footwell lamp and the diagnostic multi-plug connector; then, remove the closing panel.
      32.  
      33. Remove the 4 dash center bracket bolts and the bracket.
      34.  
      35. Disconnect the 4 multi-plug connectors from the Body Control Module (BCM).
      36.  
      37. At the base of the A-post on the driver-s side, remove the ground wires from the stud.
      38.  
      39. Disconnect the multi-plug electrical connectors at the base of each A-post.
      40.  
      41. Disconnect the BCM electrical harness from the sill and move it into the dash panel so it will not hamper removal of the dash panel.
      42.  
      43. At the brake and clutch switches, disconnect the multi-plug electrical connectors and vacuum hose.
      44.  
      45. If equipped with SRS, disconnect the following items:

        The SRS harness connector from the main wiring harness
         
        The SRS harness connector from the control module
         

      46.  
      47. Remove both front wheel arch liners.
      48.  
      49. At the left wheel arch, remove the 2 air cleaner baffle scrivet fasteners and the baffle.
      50.  
      51. If equipped with SRS, disconnect both SRS crash sensor electrical connectors.
      52.  
      53. Remove the 4 battery tray bolts and the 2 air cleaner-to-valance bolts.
      54.  
      55. Raise the air cleaner and battery tray to access the crash sensor harness clips.
      56.  
      57. Disconnect the crash sensor harness-to-valance clips; then, move the harnesses into the wheel arches.
      58.  
      59. Disconnect the 3 crash sensor harness-to-underside wheel arches; then, move the harness through the bulkhead and into the dash.
      60.  
      61. At the top of the dash panel, remove the 4 dash panel-to-scuttle panel tube bolts.
      62.  
      63. Remove the dash panel-to-chassis bolts. Pull the panel rearward and support it on 50mm deep wooden blocks.
      64.  

    12.  
    13. With the dash panel supported on 50mm deep wooden blocks, remove the face level vent ducts-to-dash screws; there is a vent duct located on both sides of the dash.
    14.  
    15. Remove the face level vent ducts inserts from the heater unit.
    16.  
    17. Remove the passenger-s side blower duct.
    18.  
    19. Remove the 4 heater control panel-to-dash panel screws and remove the panel.
    20.  
    21. Disconnect the 4 multi-plug connectors from the heater control panel and remove the control panel.
    22.  
    23. Remove the 5 center switch assembly-to-dash screws and remove the center switch assembly.
    24.  
    25. Disconnect the multi-plug connectors from the solar sensor and the alarm LED; then push the leads into the dash ducting.
    26.  
    27. Disconnect the harness-to-dash ducting clip; then, position the solar sensor/LED harness aside.
    28.  
    29. Disconnect the water temperature sensor-to-heater core inlet pipe clip and position the sensor aside.
    30.  
    31. Disconnect the multi-plug connector from the evaporator sensor.
    32.  
    33. Disconnect the 2 harness-to-heater base clips.
    34.  
    35. Remove the 4 heater housing-to-dash frame bolts.
    36.  
    37. Using an assistant, hold the harness away and remove the heater housing.
    38.  
    39. Remove the right side duct-to-heater/air conditioning housing screws and the duct.
    40.  
    41. Remove the heater pipe bracket screw.
    42.  
    43. Remove the 2 right side servo-to-heater/air conditioning housing screws and the servo.
    44.  
    45. Remove the heater core/pipe assembly-to-heater/air conditioning housing clips and the heater core/pipe assembly.
    46.  
    47. If installing a new heater core, remove the 2 heater core-to-heater pipe assembly screws and separate the heater pipe assembly. Discard the O-rings.

      Click image to see an enlarged view

      Fig. View of the center switch assembly-Range Rover



      Click image to see an enlarged view

      Fig. View of the heater/air conditioning housing assembly and related components-Range Rover



      Click image to see an enlarged view

      Fig. View of the heater/air conditioning housing-Range Rover



      Click image to see an enlarged view

      Fig. View of the heater core, heater tubes and seals-Range Rover

    48.  

    To install:

    1. If installing a new heater core, install new O-rings, the heater pipe assembly and the 2 heater core-to-heater pipe assembly screws.
    2.  
    3. Install the heater core/pipe assembly and the heater core/pipe assembly-to-heater/air conditioning housing clips.
    4.  
    5. Install the right side servo and the 2 servo-to-heater/air conditioning housing screws.
    6.  
    7. Install the heater pipe bracket screw.
    8.  
    9. Install the right side duct and the duct-to-heater/air conditioning housing screws.
    10.  
    11. Using an assistant, install the heater housing.
    12.  
    13. Install the 4 heater housing-to-dash frame bolts.
    14.  
    15. Connect the 2 harness-to-heater base clips.
    16.  
    17. Connect the multi-plug connector to the evaporator sensor.
    18.  
    19. Connect the water temperature sensor-to-heater core inlet pipe clip.
    20.  
    21. Connect the harness-to-dash ducting clip.
    22.  
    23. Connect the multi-plug connectors to the solar sensor and the alarm LED.
    24.  
    25. Install the center switch assembly and the 5 center switch assembly-to-dash screws.
    26.  
    27. Install the control panel and connect the 4 multi-plug connectors to the heater control panel.
    28.  
    29. Install the heater control panel and the 4 panel-to-dash panel screws.
    30.  
    31. Install the passenger-s side blower duct.
    32.  
    33. Install the face level vent ducts inserts to the heater unit.
    34.  
    35. With the dash panel supported on 50mm deep wooden blocks, install the face level vent ducts-to-dash screws; there is a vent duct located on both sides of the dash.
    36.  
    37. Install the dash panel assembly by performing the following procedures:
      1. Push the panel forward and support it on 50mm deep wooden blocks. Install the dash panel-to-chassis bolts.
      2.  
      3. At the top of the dash panel, install the 4 dash panel-to-scuttle panel tube bolts.
      4.  
      5. Connect the 3 crash sensor harness-to-underside wheel arches.
      6.  
      7. Connect the crash sensor harness-to-valance clips.
      8.  
      9. Install the 4 battery tray bolts and the 2 air cleaner-to-valance bolts.
      10.  
      11. If equipped with SRS, connect both SRS crash sensor electrical connectors.
      12.  
      13. At the left wheel arch, install the air cleaner baffle and the 2 baffle scrivet fasteners.
      14.  
      15. Install both front wheel arch liners.
      16.  
      17. If equipped with SRS, connect the following items:

        The SRS harness connector to the main wiring harness
         
        The SRS harness connector to the control module
         

      18.  
      19. At the brake and clutch switches, connect the multi-plug electrical connectors and vacuum hose.
      20.  
      21. Connect the BCM electrical harness to the sill.
      22.  
      23. Connect the multi-plug electrical connectors at the base of each A-post.
      24.  
      25. At the base of the A-post on the driver-s side, install the ground wires to the stud.
      26.  
      27. Connect the 4 multi-plug connectors to the Body Control Module (BCM).
      28.  
      29. Install the dash center bracket and the 4 bracket bolts.
      30.  
      31. Install the closing panel; then, connect the footwell lamp and the diagnostic multi-plug connector.
      32.  
      33. Install the lower closing panel and the 2 panel-to-passenger side scrivet fasteners.
      34.  
      35. At the driver-s side, install the carpet retainer and the 4 spring clips.
      36.  
      37. Install the seat base trim, the 2 trim studs and the screw.
      38.  
      39. At the driver-s seat base trim, install the fuse cover.
      40.  
      41. At each A-post-s lower trim panel, install both trim panels, the screw and the spring clip.
      42.  
      43. If equipped with a foot rest on the driver-s side, install the foot rest and the 3 foot rest-to-A-post lower trim bolts.
      44.  
      45. Near the A-post lower trim panels, install the door aperture seal.
      46.  
      47. Install the radio.
      48.  
      49. Install the both pollen filter housings and the 8 housing screws to each housing.
      50.  
      51. Install the heater intake pollen filters.
      52.  
      53. Install the scuttle side panel and the 6 side panel-to-chassis bolts.
      54.  
      55. At the passenger-s side, connect the heated front screen multi-plug connector and install the clip.
      56.  
      57. Install the steering column.
      58.  
      59. Install the wiper motor and linkage.
      60.  
      61. Install the center console.
      62.  

    38.  
    39. If equipped with air conditioning, perform the following procedure:
      1. Lubricate and install new O-rings and connect the pipes.
      2.  
      3. Install the refrigerant pipes mount-to-evaporator bolt.
      4.  

    40.  
    41. Connect the heater hoses to the heater tubes and install the hose clips.
    42.  
    43. Refill the cooling system.
    44.  
    45. If the battery was removed, install it.
    46.  
    47. Connect the positive (+) battery cable; then, the negative (() battery cable.
    48.  
    49. Evacuate and charge the air conditioning system.
    50.  
    51. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    52.  

    1. Disconnect the negative (() battery cable; then the positive (+) battery cable.
      NOTE
      Wait at least 20 minutes for the air bag(s) to discharge before performing any work on the system(s).

    2.  
    3. If equipped with SRS, remove the battery.
    4.  
    5. Drain the cooling system into a clean container for reuse.
    6.  
    7. Loosen the hose clips and disconnect the heater hoses from the heater tubes.
    8.  
    9. If equipped with air conditioning, perform the following procedure:
      1. Discharge and recover the air conditioning refrigerant.
      2.  
      3. Remove the refrigerant pipes mount-to-evaporator bolt
      4.  
      5. Disconnect the pipes and discard the O-rings.
      6.  
      7. Plug the openings to prevent contamination.
      8.  

    10.  
    11. Remove the dash panel assembly by performing the following procedures:
      1. Remove the center console.
      2.  
      3. Remove the wiper motor and linkage.
      4.  
      5. Remove the steering column.
      6.  
      7. At the passenger-s side, remove the clip and disconnect the heated front screen multi-plug connector.
      8.  
      9. Remove the 6 scuttle side panel-to-chassis bolts and the side panel.
      10.  
      11. Remove the heater intake pollen filters.
      12.  
      13. Remove the 8 pollen filter housing screws from each housing and remove both housings.
      14.  
      15. Remove the radio.
      16.  
      17. Near the A-post lower trim panels, remove the door aperture seal.
      18.  
      19. If equipped with a footrest on the driver-s side, remove the 3 foot rest-to-A-post lower trim bolts and remove the foot rest.
      20.  
      21. At each A-post-s lower trim panel, remove the screw and release the spring clip and remove both trim panels.
      22.  
      23. At the driver-s seat base trim, remove the fuse cover.
      24.  
      25. Remove the screw, the 2 trim studs and the seat base trim.
      26.  
      27. At the driver-s side, release the 4 spring clips and remove the carpet retainer.
      28.  
      29. Remove the 2 lower closing panel-to-passenger side scrivet fasteners and the panel.
      30.  
      31. Release the closing panel, disconnect the footwell lamp and the diagnostic multi-plug connector; then, remove the closing panel.
      32.  
      33. Remove the 4 dash center bracket bolts and the bracket.
      34.  
      35. Disconnect the 4 multi-plug connectors from the Body Control Module (BCM).
      36.  
      37. At the base of the A-post on the driver-s side, remove the ground wires from the stud.
      38.  
      39. Disconnect the multi-plug electrical connectors at the base of each A-post.
      40.  
      41. Disconnect the BCM electrical harness from the sill and move it into the dash panel so it will not hamper removal of the dash panel.
      42.  
      43. At the brake and clutch switches, disconnect the multi-plug electrical connectors and vacuum hose.
      44.  
      45. If equipped with SRS, disconnect the following items:

        The SRS harness connector from the main wiring harness
         
        The SRS harness connector from the control module
         

      46.  
      47. Remove both front wheel arch liners.
      48.  
      49. At the left wheel arch, remove the 2 air cleaner baffle scrivet fasteners and the baffle.
      50.  
      51. If equipped with SRS, disconnect both SRS crash sensor electrical connectors.
      52.  
      53. Remove the 4 battery tray bolts and the 2 air cleaner-to-valance bolts.
      54.  
      55. Raise the air cleaner and battery tray to access the crash sensor harness clips.
      56.  
      57. Disconnect the crash sensor harness-to-valance clips; then, move the harnesses into the wheel arches.
      58.  
      59. Disconnect the 3 crash sensor harness-to-underside wheel arches; then, move the harness through the bulkhead and into the dash.
      60.  
      61. At the top of the dash panel, remove the 4 dash panel-to-scuttle panel tube bolts.
      62.  
      63. Remove the dash panel-to-chassis bolts. Pull the panel rearward and support it on 50mm deep wooden blocks.
      64.  

    12.  
    13. With the dash panel supported on 50mm deep wooden blocks, remove the face level vent ducts-to-dash screws; there is a vent duct located on both sides of the dash.
    14.  
    15. Remove the face level vent ducts inserts from the heater unit.
    16.  
    17. Remove the passenger-s side blower duct.
    18.  
    19. Remove the 4 heater control panel-to-dash panel screws and remove the panel.
    20.  
    21. Disconnect the 4 multi-plug connectors from the heater control panel and remove the control panel.
    22.  
    23. Remove the 5 center switch assembly-to-dash screws and remove the center switch assembly.
    24.  
    25. Disconnect the multi-plug connectors from the solar sensor and the alarm LED; then push the leads into the dash ducting.
    26.  
    27. Disconnect the harness-to-dash ducting clip; then, position the solar sensor/LED harness aside.
    28.  
    29. Disconnect the water temperature sensor-to-heater core inlet pipe clip and position the sensor aside.
    30.  
    31. Disconnect the multi-plug connector from the evaporator sensor.
    32.  
    33. Disconnect the 2 harness-to-heater base clips.
    34.  
    35. Remove the 4 heater housing-to-dash frame bolts.
    36.  
    37. Using an assistant, hold the harness away and remove the heater housing.
    38.  
    39. Remove the right side duct-to-heater/air conditioning housing screws and the duct.
    40.  
    41. Remove the heater pipe bracket screw.
    42.  
    43. Remove the 2 right side servo-to-heater/air conditioning housing screws and the servo.
    44.  
    45. Remove the heater core/pipe assembly-to-heater/air conditioning housing clips and the heater core/pipe assembly.
    46.  
    47. If installing a new heater core, remove the 2 heater core-to-heater pipe assembly screws and separate the heater pipe assembly. Discard the O-rings.

      Click image to see an enlarged view

      Fig. View of the center switch assembly-Range Rover



      Click image to see an enlarged view

      Fig. View of the heater/air conditioning housing assembly and related components-Range Rover



      Click image to see an enlarged view

      Fig. View of the heater/air conditioning housing-Range Rover



      Click image to see an enlarged view

      Fig. View of the heater core, heater tubes and seals-Range Rover

    48.  

    To install:

    1. If installing a new heater core, install new O-rings, the heater pipe assembly and the 2 heater core-to-heater pipe assembly screws.
    2.  
    3. Install the heater core/pipe assembly and the heater core/pipe assembly-to-heater/air conditioning housing clips.
    4.  
    5. Install the right side servo and the 2 servo-to-heater/air conditioning housing screws.
    6.  
    7. Install the heater pipe bracket screw.
    8.  
    9. Install the right side duct and the duct-to-heater/air conditioning housing screws.
    10.  
    11. Using an assistant, install the heater housing.
    12.  
    13. Install the 4 heater housing-to-dash frame bolts.
    14.  
    15. Connect the 2 harness-to-heater base clips.
    16.  
    17. Connect the multi-plug connector to the evaporator sensor.
    18.  
    19. Connect the water temperature sensor-to-heater core inlet pipe clip.
    20.  
    21. Connect the harness-to-dash ducting clip.
    22.  
    23. Connect the multi-plug connectors to the solar sensor and the alarm LED.
    24.  
    25. Install the center switch assembly and the 5 center switch assembly-to-dash screws.
    26.  
    27. Install the control panel and connect the 4 multi-plug connectors to the heater control panel.
    28.  
    29. Install the heater control panel and the 4 panel-to-dash panel screws.
    30.  
    31. Install the passenger-s side blower duct.
    32.  
    33. Install the face level vent ducts inserts to the heater unit.
    34.  
    35. With the dash panel supported on 50mm deep wooden blocks, install the face level vent ducts-to-dash screws; there is a vent duct located on both sides of the dash.
    36.  
    37. Install the dash panel assembly by performing the following procedures:
      1. Push the panel forward and support it on 50mm deep wooden blocks. Install the dash panel-to-chassis bolts.
      2.  
      3. At the top of the dash panel, install the 4 dash panel-to-scuttle panel tube bolts.
      4.  
      5. Connect the 3 crash sensor harness-to-underside wheel arches.
      6.  
      7. Connect the crash sensor harness-to-valance clips.
      8.  
      9. Install the 4 battery tray bolts and the 2 air cleaner-to-valance bolts.
      10.  
      11. If equipped with SRS, connect both SRS crash sensor electrical connectors.
      12.  
      13. At the left wheel arch, install the air cleaner baffle and the 2 baffle scrivet fasteners.
      14.  
      15. Install both front wheel arch liners.
      16.  
      17. If equipped with SRS, connect the following items:

        The SRS harness connector to the main wiring harness
         
        The SRS harness connector to the control module
         

      18.  
      19. At the brake and clutch switches, connect the multi-plug electrical connectors and vacuum hose.
      20.  
      21. Connect the BCM electrical harness to the sill.
      22.  
      23. Connect the multi-plug electrical connectors at the base of each A-post.
      24.  
      25. At the base of the A-post on the driver-s side, install the ground wires to the stud.
      26.  
      27. Connect the 4 multi-plug connectors to the Body Control Module (BCM).
      28.  
      29. Install the dash center bracket and the 4 bracket bolts.
      30.  
      31. Install the closing panel; then, connect the footwell lamp and the diagnostic multi-plug connector.
      32.  
      33. Install the lower closing panel and the 2 panel-to-passenger side scrivet fasteners.
      34.  
      35. At the driver-s side, install the carpet retainer and the 4 spring clips.
      36.  
      37. Install the seat base trim, the 2 trim studs and the screw.
      38.  
      39. At the driver-s seat base trim, install the fuse cover.
      40.  
      41. At each A-post-s lower trim panel, install both trim panels, the screw and the spring clip.
      42.  
      43. If equipped with a foot rest on the driver-s side, install the foot rest and the 3 foot rest-to-A-post lower trim bolts.
      44.  
      45. Near the A-post lower trim panels, install the door aperture seal.
      46.  
      47. Install the radio.
      48.  
      49. Install the both pollen filter housings and the 8 housing screws to each housing.
      50.  
      51. Install the heater intake pollen filters.
      52.  
      53. Install the scuttle side panel and the 6 side panel-to-chassis bolts.
      54.  
      55. At the passenger-s side, connect the heated front screen multi-plug connector and install the clip.
      56.  
      57. Install the steering column.
      58.  
      59. Install the wiper motor and linkage.
      60.  
      61. Install the center console.
      62.  

    38.  
    39. If equipped with air conditioning, perform the following procedure:
      1. Lubricate and install new O-rings and connect the pipes.
      2.  
      3. Install the refrigerant pipes mount-to-evaporator bolt.
      4.  

    40.  
    41. Connect the heater hoses to the heater tubes and install the hose clips.
    42.  
    43. Refill the cooling system.
    44.  
    45. If the battery was removed, install it.
    46.  
    47. Connect the positive (+) battery cable; then, the negative (() battery cable.
    48.  
    49. Evacuate and charge the air conditioning system.
    50.  
    51. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    52.  

    Range Rover (2000-02)



    1. Disconnect the negative (() battery cable; then the positive (+) battery cable.
      NOTE
      Wait at least 20 minutes for the air bag(s) to discharge before performing any work on the system(s).

    2.  
    3. If equipped with SRS, remove the battery.
    4.  
    5. Drain the cooling system into a clean container for reuse.
    6.  
    7. Loosen the hose clips and disconnect the heater hoses from the heater tubes.
    8.  
    9. If equipped with air conditioning, perform the following procedure:
      1. Discharge and recover the air conditioning refrigerant.
      2.  
      3. Remove the refrigerant pipes mount-to-evaporator bolt
      4.  
      5. Disconnect the pipes and discard the O-rings.
      6.  
      7. Plug the openings to prevent contamination.
      8.  

    10.  
    11. Remove the dash panel assembly by performing the following procedures:
      1. Remove the center console.
      2.  
      3. Remove the wiper motor and linkage.
      4.  
      5. Remove the steering column.
      6.  
      7. At the passenger-s side, remove the clip and disconnect the heated front screen multiplug connector.
      8.  
      9. Remove the 6 scuttle side panel-to-chassis bolts and the side panel.
      10.  
      11. Remove the heater intake pollen filters.
      12.  
      13. Remove the 8 pollen filter housing screws from each housing and remove both housings.
      14.  
      15. Remove the radio.
      16.  
      17. Near the A-post lower trim panels, remove the door aperture seal.
      18.  
      19. If equipped with a footrest on the driver-s side, remove the 3 foot rest-to-A-post lower trim bolts and remove the foot rest.
      20.  
      21. At each A-post-s lower trim panel, remove the screw and release the spring clip and remove both trim panels.
      22.  
      23. At the driver-s seat base trim, remove the fuse cover.
      24.  
      25. Remove the screw, the 2 trim studs and the seat base trim.
      26.  
      27. At the driver-s side, release the 4 spring clips and remove the carpet retainer.
      28.  
      29. Remove the 2 lower closing panel-to-passenger side scrivet fasteners and the panel.
      30.  
      31. Release the closing panel, disconnect the footwell lamp and the diagnostic multiplug connector; then, remove the closing panel.
      32.  
      33. Remove the 4 dash center bracket bolts and the bracket.
      34.  
      35. Disconnect the 4 multiplug connectors from the Body Control Module (BCM).
      36.  
      37. At the base of the A-post on the driver-s side, remove the ground wires from the stud.
      38.  
      39. Disconnect the multiplug electrical connectors at the base of each A-post.
      40.  
      41. Disconnect the BCM electrical harness from the sill and move it into the dash panel so it will not hamper removal of the dash panel.
      42.  
      43. At the brake and clutch switches, disconnect the multiplug electrical connectors and vacuum hose.
      44.  
      45. If equipped with SRS, disconnect the following items:

        The SRS harness connector from the main wiring harness
         
        The SRS harness connector from the control module
         

      46.  
      47. Remove both front wheel arch liners.
      48.  
      49. At the left wheel arch, remove the 2 air cleaner baffle scrivet fasteners and the baffle.
      50.  
      51. If equipped with SRS, disconnect both SRS crash sensor electrical connectors.
      52.  
      53. Remove the 4 battery tray bolts and the 2 air cleaner-to-valance bolts.
      54.  
      55. Raise the air cleaner and battery tray to access the crash sensor harness clips.
      56.  
      57. Disconnect the crash sensor harness-to-valance clips; then, move the harnesses into the wheel arches.
      58.  
      59. Disconnect the 3 crash sensor harness-to-underside wheel arches; then, move the harness through the bulkhead and into the dash.
      60.  
      61. At the top of the dash panel, remove the 4 dash panel-to-scuttle panel tube bolts.
      62.  
      63. Remove the dash panel-to-chassis bolts. Pull the panel rearward and support it on 50mm deep wooden blocks.
      64.  

    12.  
    13. With the dash panel supported on 50mm deep wooden blocks, remove the face level vent ducts-to-dash screws; there is a vent duct located on both sides of the dash.
    14.  
    15. Remove the face level vent ducts inserts from the heater unit.
    16.  
    17. Remove the passenger-s side blower duct.
    18.  
    19. Remove the 4 heater control panel-to-dash panel screws and remove the panel.
    20.  
    21. Disconnect the 4 multiplug connectors from the heater control panel and remove the control panel.
    22.  
    23. Remove the 5 center switch assembly-to-dash screws and remove the center switch assembly.
    24.  
    25. Disconnect the multiplug connectors from the solar sensor and the alarm LED; then push the leads into the dash ducting.
    26.  
    27. Disconnect the harness-to-dash ducting clip; then, position the solar sensor/LED harness aside.
    28.  
    29. Disconnect the water temperature sensor-to-heater core inlet pipe clip and position the sensor aside.
    30.  
    31. Disconnect the multiplug connector from the evaporator sensor.
    32.  
    33. Disconnect the 2 harness-to-heater base clips.
    34.  
    35. Remove the 4 heater housing-to-dash frame bolts.
    36.  
    37. Using an assistant, hold the harness away and remove the heater housing.
    38.  
    39. Remove the right side duct-to-heater/air conditioning housing screws and the duct.
    40.  
    41. Remove the heater pipe bracket screw.
    42.  
    43. Remove the 2 right side servo-to-heater/air conditioning housing screws and the servo.
    44.  
    45. Remove the heater core/pipe assembly-to-heater/air conditioning housing clips and the heater core/pipe assembly.
    46.  
    47. If installing a new heater core, remove the 2 heater core-to-heater pipe assembly screws and separate the heater pipe assembly. Discard the O-rings.

      Click image to see an enlarged view

      Fig. View of the center switch assembly-Range Rover (2000-02)

    48.  

    To install:

    1. If installing a new heater core, install new O-rings, the heater pipe assembly and the 2 heater core-to-heater pipe assembly screws.
    2.  
    3. Install the heater core/pipe assembly and the heater core/pipe assembly-to-heater/air conditioning housing clips.
    4.  
    5. Install the right side servo and the 2 servo-to-heater/air conditioning housing screws.
    6.  
    7. Install the heater pipe bracket screw.
    8.  
    9. Install the right side duct and the duct-to-heater/air conditioning housing screws.
    10.  
    11. Using an assistant, install the heater housing.
    12.  
    13. Install the 4 heater housing-to-dash frame bolts.
    14.  
    15. Connect the 2 harness-to-heater base clips.
    16.  
    17. Connect the multiplug connector to the evaporator sensor.
    18.  
    19. Connect the water temperature sensor-to-heater core inlet pipe clip.
    20.  
    21. Connect the harness-to-dash ducting clip.
    22.  
    23. Connect the multiplug connectors to the solar sensor and the alarm LED.
    24.  
    25. Install the center switch assembly and the 5 center switch assembly-to-dash screws.
    26.  
    27. Install the control panel and connect the 4 multiplug connectors to the heater control panel.
    28.  
    29. Install the heater control panel and the 4 panel-to-dash panel screws.
    30.  
    31. Install the passenger-s side blower duct.
    32.  
    33. Install the face level vent ducts inserts to the heater unit.
    34.  
    35. With the dash panel supported on 50mm deep wooden blocks, install the face level vent ducts-to-dash screws; there is a vent duct located on both sides of the dash.
    36.  
    37. Install the dash panel assembly by performing the following procedures:
      1. Push the panel forward and support it on 50mm deep wooden blocks. Install the dash panel-to-chassis bolts.
      2.  
      3. At the top of the dash panel, install the 4 dash panel-to-scuttle panel tube bolts.
      4.  
      5. Connect the 3 crash sensor harness-to-underside wheel arches.
      6.  
      7. Connect the crash sensor harness-to-valance clips.
      8.  
      9. Install the 4 battery tray bolts and the 2 air cleaner-to-valance bolts.
      10.  
      11. If equipped with SRS, connect both SRS crash sensor electrical connectors.
      12.  
      13. At the left wheel arch, install the air cleaner baffle and the 2 baffle scrivet fasteners.
      14.  
      15. Install both front wheel arch liners.
      16.  
      17. If equipped with SRS, connect the following items:

        The SRS harness connector to the main wiring harness
         
        The SRS harness connector to the control module
         

      18.  
      19. At the brake and clutch switches, connect the multiplug electrical connectors and vacuum hose.
      20.  
      21. Connect the BCM electrical harness to the sill.
      22.  
      23. Connect the multiplug electrical connectors at the base of each A-post.
      24.  
      25. At the base of the A-post on the driver-s side, install the ground wires to the stud.
      26.  
      27. Connect the 4 multiplug connectors to the Body Control Module (BCM).
      28.  
      29. Install the dash center bracket and the 4 bracket bolts.
      30.  
      31. Install the closing panel; then, connect the footwell lamp and the diagnostic multiplug connector.
      32.  
      33. Install the lower closing panel and the 2 panel-to-passenger side scrivet fasteners.
      34.  
      35. At the driver-s side, install the carpet retainer and the 4 spring clips.
      36.  
      37. Install the seat base trim, the 2 trim studs and the screw.
      38.  
      39. At the driver-s seat base trim, install the fuse cover.
      40.  
      41. At each A-post-s lower trim panel, install both trim panels, the screw and the spring clip.
      42.  
      43. If equipped with a foot rest on the driver-s side, install the foot rest and the 3 foot rest-to-A-post lower trim bolts.
      44.  
      45. Near the A-post lower trim panels, install the door aperture seal.
      46.  
      47. Install the radio.
      48.  
      49. Install the both pollen filter housings and the 8 housing screws to each housing.
      50.  
      51. Install the heater intake pollen filters.
      52.  
      53. Install the scuttle side panel and the 6 side panel-to-chassis bolts.
      54.  
      55. At the passenger-s side, connect the heated front screen multiplug connector and install the clip.
      56.  
      57. Install the steering column.
      58.  
      59. Install the wiper motor and linkage.
      60.  
      61. Install the center console.
      62.  

    38.  
    39. If equipped with air conditioning, perform the following procedure:
      1. Lubricate and install new O-rings and connect the pipes.
      2.  
      3. Install the refrigerant pipes mount-to-evaporator bolt.
      4.  

    40.  
    41. Connect the heater hoses to the heater tubes and install the hose clips.
    42.  
    43. Refill the cooling system.
    44.  
    45. If the battery was removed, install it.
    46.  
    47. Connect the positive (+) battery cable; then, the negative (() battery cable.
    48.  
    49. Evacuate and charge the air conditioning system.
    50.  
    51. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    52.  

    Freelander (2002-04)



    1. Drain cooling system.
    2.  
    3. Release 2 clips securing heater hoses to heater and disconnect hoses.
    4.  
    5. Remove dash panel by the following steps:
      1. Remove front console
      2.  
      3. Remove rotary couple for air bag system:

        Steering wheel centered and wheels straight ahead
         
        Remove steering wheel
         
        Remove steering column covers
         
        Disconnect 2 connectors from rotary coupler
         
        Remove 4 screws and remove rotary coupler
         

      4.  
      5. Remove the 4 connectors from the wiper/indicator switch.
      6.  
      7. Loosen the clamping screw and remove the wiper/indicator switch.
      8.  
      9. Remove the 2 screws from the steering column lower finish panel and remove panel.
      10.  
      11. Open the driver side glove box lid and remove the fuse box cover.
      12.  
      13. Disconnect 2 connectors from the fuse box. Close the glove box.
      14.  
      15. Remove the clock.
      16.  
      17. Remove the upper trim panels from both A-pillars.
      18.  
      19. Remove the passenger side airbag module by removing or disconnecting the following:

        2 screws holding airbag lower finish panel
         
        4 Torx® bolts hold airbag module to dash panel
         
        Airbag connector from airbag module
         
        Remove airbag module and store properly
         

      20.  
      21. Disconnect the 2 main harness-to-dash connectors through the center console opening.
      22.  
      23. Remove the 12 dash panel retaining bolts.
      24.  
      25. With an assistant, carefully remove the dash panel.
      26.  

    6.  
    7. Remove the 2 bolts from the console support bracket, release the 2 relays and remove the brackets from in front of the shift lever.
    8.  
    9. Disconnect the 4 connectors from the heater controls.
    10.  
    11. Disconnect the multiplug from the heater assembly and release the diagnostic connector.
    12.  
    13. Disconnect the multiplug from the evaporator.
    14.  
    15. Disconnect the ducts from the left and right outer face level vents.
    16.  
    17. Detach the left and right defogger vents.
    18.  
    19. Release the air inlet connector hose.
    20.  
    21. Disconnect the harness from the heater housing.
    22.  
    23. Remove 2 nuts and 1 bolt and remove the heater assembly.
      NOTE
      Do not carry out further dismantling if component is removed for access only.

    24.  
    25. Disconnect the 2 connectors from the heater controls.
    26.  
    27. Release the air blend control cable from the lever and abutment.
    28.  
    29. Release the air distribution cable from the lever and abutment.
    30.  
    31. Remove the heater controls.
    32.  
    33. Remove screw securing pipe clamp to the heater casing and remove clamp.
    34.  
    35. Remove 2 screws from core cover and remove cover.
    36.  
    37. Remove the heater core.
    38.  

    To install:

    1. Fit the heater core to the heater assembly.
    2.  
    3. Fit the core cover and secure with screws.
    4.  
    5. Fit pipe clamp and secure with screw.
    6.  
    7. Install the heater assembly.
    8.  
    9. Position the heater controls to replacement heater, if necessary.
    10.  
    11. Connect the air distribution cable to lever and abutment.
    12.  
    13. Connect the air blend cable to lever and abutment.
    14.  
    15. Connect the connectors to heater controls.
    16.  
    17. Position the heater and secure with nuts and bolt.
    18.  
    19. Position harness and connect to clips on heater.
    20.  
    21. Fit the air inlet connector hose.
    22.  
    23. Fit the right side defogger vent duct to heater.
    24.  
    25. Fit the right side outer face level vent duct to heater and secure to body with bolt.
    26.  
    27. Fit the left side defogger vent duct to heater.
    28.  
    29. Fit left side outer face level vent duct to heater and secure to body with bolt.
    30.  
    31. Connect the multiplug to evaporator.
    32.  
    33. Connect the multiplug to the heater and secure the diagnostic socket.
    34.  
    35. Connect the connectors to heater controls.
    36.  
    37. Fit console support bracket and secure with bolts.
    38.  
    39. Fit relays to console support bracket.
    40.  
    41. Install the dash panel in reverse of the removal procedure.
      CAUTION
      Use special care to ensure the airbag module is properly restored.

    42.  
    43. Connect the heater hoses and secure with clips.
    44.  
    45. Refill the cooling system.
    46.  
    47. Operate the engine to normal operating temperatures. Test the controls and check for leaks.

      Click image to see an enlarged view

      Fig. Removing passenger airbag module-Freelander



      Click image to see an enlarged view

      Fig. Identifying key components on the heater assembly-Freelander

    48.  

     
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