light LAND ROVER FREELANDER 2001 Repair Manual

PANEL REPAIRS
REPAIRS 77-2-31
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit insulation pads to engine bulkhead.
2.Position front carpet and fit treadplate to front
door aperture. 3. Driver's side: Fit clutch pedal box.
4. Driver's side: Fit brake pedal box and brake
servo.
5. Driver's side: Fit passenger compartment fuse
box.
6. LH side: Fit horn.

+ SECURITY, REPAIRS, Horn.
7. LH side: Fit air intake hose.
8. LH side: Fit battery. Do not connect battery
earth lead.

+ CHARGING AND STARTING,
REPAIRS, Battery.
9. LH side: Fit LH engine mounting to body.
10. LH side: Fit front bumper LH support bracket.
11. RH side: Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
12. RH side: Fit RH engine mounting to body.
13. RH side: Fit front bumper RH support bracket.
14.Fit fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
15.Fit PAS rack.

+ STEERING, REPAIRS, Power
steering rack.
16.Fit engine and gearbox.

+ ENGINE - K SERIES KV6, REPAIRS,
Engine and automatic gearbox - up to 03MY.
17.Fit front suspension rear beam.
18.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
19.Fit engine bay shield.
20.Fit headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
21.Secure headlamp wiring.
22.Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
23.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
24.Fit front bumper armature.
25.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
26.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
27.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
28.Connect all ECUs.
29.Connect alternator.
30.Connect battery earth lead.

PANEL REPAIRS
77-2-32 REPAIRS
Front sidemember (front section)
In this procedure, the front section of the front
sidemember closing panel and the related
crossmember to sidemember gusset plate are
replaced in conjunction with the front sidemember.
Remove
1.Disconnect battery earth lead.
2.Disconnect all ECUs.
3.Remove road wheel(s).
4.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
6.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
7.Remove PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
8.Remove headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
9.Release wiring to headlamp and position aside.
10.Remove engine bay shield.
11.Remove front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
12. LH side: Remove front bumper LH support
bracket.
13. LH side: Remove ECM.
14. LH side: Remove battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
15. LH side: Remove air cleaner.
16. LH side: Remove air intake hose.
17. LH side: Remove horn.

+ SECURITY, REPAIRS, Horn.
18. RH side: Remove front bumper RH support
bracket.
19. RH side: Remove windscreen washer
reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
20. RH side: Remove alternator.

+ CHARGING AND STARTING,
REPAIRS, Alternator - KV6.
21. RH side: Remove PAS pump.

+ STEERING, REPAIRS, Pump -
steering - KV6.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.

PANEL REPAIRS
REPAIRS 77-2-33
Refit
1. LH side: Fit horn.

+ SECURITY, REPAIRS, Horn.
2. LH side: Fit air intake hose.
3. LH side: Fit air cleaner.
4. LH side: Fit battery carrier. Do not connect
battery earth lead.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
5. LH side: Fit ECM.
6. LH side: Fit front bumper LH support bracket.
7. RH side: Fit PAS pump.

+ STEERING, REPAIRS, Pump -
steering - KV6.
8. RH side: Fit alternator.

+ CHARGING AND STARTING,
REPAIRS, Alternator - KV6.
9. RH side: Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
10. RH side: Fit front bumper RH support bracket.
11.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
12.Fit engine bay shield.
13.Fit headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
14. Secure headlamp wiring.
15.Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
16.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
17.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
18.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
19.Connect all ECUs.
20.Connect battery earth lead.
Front valance assembly
Remove
1.Disconnect battery earth lead.
2.Disconnect all ECUs.
3.Remove road wheel(s).
4.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
6.Remove front bumper armature.
7.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
8.Remove PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
9.Remove headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
10.Release wiring to headlamp and position aside.
11.Remove engine bay shield.
12.Remove front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
13.Remove front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
14.Remove front suspension rear beam.
15.Remove engine and gearbox.

+ ENGINE - K SERIES KV6, REPAIRS,
Engine and automatic gearbox - up to 03MY.
16.Remove front damper.

+ FRONT SUSPENSION, REPAIRS,
Damper.
17.Remove PAS rack.

+ STEERING, REPAIRS, Power
steering rack.
18.Remove fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
19. LH side: Remove front bumper LH support
bracket.
20. LH side: Remove air cleaner.
21. LH side: Remove air intake hose.
22. LH side: Remove ECM.
23. LH side: Remove engine compartment
fusebox.
24. LH side: Remove battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
25. LH side: Remove engine compartment fuse
box and related wiring.

PANEL REPAIRS
REPAIRS 77-2-35
29.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
30.Fit engine bay shield.
31.Fit headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
32.Secure headlamp wiring. Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
33.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
34.Fit front bumper armature.
35.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
36.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
37.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
38.Connect all ECUs.
39.Connect battery earth lead.

PANEL REPAIRS
77-2-36 REPAIRS
Valance upper front
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
6.Remove front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
7.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
8.Remove headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
9.Release wiring from valance and position
aside.
10. LH side: Remove ECM.
11. LH side: Remove battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
12. RH side: Remove PAS fluid reservoir.
13. RH side: Remove brake pipes from valance.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown. Refit
1. LH side: Fit battery. Do not connect earth lead.

+ CHARGING AND STARTING,
REPAIRS, Battery.
2. LH side: Fit ECM.
3. RH side: Fit PAS fluid reservoir.
4. RH side: Fit brake pipes to valance. Bleed
brakes.

+ BRAKES, ADJUSTMENTS, Brake
bleed.
5.Secure wiring to valance.
6.Fit headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
7.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
8.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
9.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
10.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
11.Connect all ECUs.
12.Connect alternator.
13.Connect battery earth lead.

PANEL REPAIRS
REPAIRS 77-2-37
Valance front
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
6.Remove engine bay shield.
7.Remove front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
8.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
9.Remove front bumper support bracket.
10.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
11.Remove headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
12.Release wiring to headlamp and position aside.
13. LH side: Remove air cleaner.
14. LH side: Remove air intake hose.
15. LH side: Remove ECM.
16. LH side: Remove battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
17. LH side: Remove engine compartment fuse
box and related wiring.
18. LH side: Remove LH front brake pipe.
19. RH side: Remove PAS fluid reservoir.
20. RH side: Remove RH front brake pipe.
21. RH side: Remove windscreen washer
reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
22. RH side: Remove PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.

PANEL REPAIRS
77-2-38 REPAIRS
Refit
1. LH side: Fit LH front brake pipe. Bleed brake
system.

+ BRAKES, ADJUSTMENTS, Brake
bleed.
2. LH side: Fit engine compartment fuse box and
related wiring.
3. LH side: Fit battery carrier. Do not connect
battery earth lead.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
4. LH side: Fit ECM.
5. LH side: Fit air intake hose.
6. LH side: Fit air cleaner.
7. RH side: Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
8. RH side: Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
9. RH side: Fit RH front brake pipe. Bleed brake
system.

+ BRAKES, ADJUSTMENTS, Brake
bleed.
10. RH side: Fit PAS fluid reservoir.
11.Fit headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
12.Secure headlamp wiring.
13.Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
14.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
15.Fit front bumper support bracket.
16.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
17.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
18.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
19.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
20.Connect all ECUs.
21.Connect alternator.
22.Connect battery earth lead.

PANEL REPAIRS
REPAIRS 77-2-39
Valance outer reinforcement
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
6.Remove front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
7.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
8.Remove headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
9.Release wiring from valance and position
aside.
10. LH side: Remove battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
11. LH side: Remove ECM.
12. LH side: Remove relay module.
13. LH side: Remove battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
14. LH side: Remove engine compartment fuse
box and related wiring.
15. RH side: Remove PAS fluid reservoir.
16. RH side: Remove brake pipes from valance. Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1. LH side: Fit engine compartment fuse box and
related wiring.
2. LH side: Fit battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
3. LH side: Fit relay module.
4. LH side: Fit ECM.
5. LH side: Fit battery. Do not connect earth lead.

+ CHARGING AND STARTING,
REPAIRS, Battery.
6. RH side: Fit PAS fluid reservoir.
7. RH side: Fit brake pipes to valance. Bleed
brakes.

+ BRAKES, ADJUSTMENTS, Brake
bleed.
8.Secure wiring to valance.
9.Fit headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
10.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
11.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
12.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
13.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
14.Connect all ECUs.
15.Connect alternator.
16.Connect battery earth lead.

PANEL REPAIRS
77-2-48 REPAIRS
Refit
1.Secure vehicle harness to inner sill.
2.Position carpet to inner sill.
3.Fit side door aperture seal(s).
4.Fit treadplate from side door aperture(s).
5.Fit rear seat.

+ SEATS, REPAIRS, Rear seat - LH.
6.Fit front seat.

+ SEATS, REPAIRS, Front seat.
7.Fit front door striker to 'B/C' post.
8.Fit 'B/C' post lower finisher.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim finisher - 'B' post - lower - 5
door.
9.Fit front seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Automatic belt assembly - front - 5 door.
10.Fit headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
11.Fit rear door.

+ DOORS, REPAIRS, Door assembly
- rear - remove for access & refit.

+ SEATS, REPAIRS, Rear seat - RH.
12.Connect all ECUs.
13.Connect alternator.
14.Connect battery earth lead.
Complete rear quarter - 3 door
In this procedure, the rear outer body side panel is
replaced in conjunction with the complete rear
quarter.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove sill lower finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Finisher - sill - lower.
6.Remove rear bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
7.Remove rear wheel arch liner.
8.Remove door striker from 'B' post.
9.Remove treadplate from front door aperture.
10.Remove front door aperture seal.
11.Release carpet from inner sill and rear
heelboard and position aside.
12.Remove soft/hard top.
13.Remove tail door aperture seal.
14.Remove rear roof panel finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Moulding - roof - 5 door.
15.Remove tail lamp.

+ LIGHTING, REPAIRS, Lamp
assembly - tail.
16.Remove rear quarter lower casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 3 door.
17.Remove rear quarter upper casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - upper
- 3 door.
18.Remove rear side seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - rear - LH.
19.Remove loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
20.Remove rear seat.

+ SEATS, REPAIRS, Rear seat - LH.

+ SEATS, REPAIRS, Rear seat - RH.
21.Remove rear body side casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - body side - rear - 3
door.
22.Remove headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.

PANEL REPAIRS
REPAIRS 77-2-49
23.Remove rear quarter vent and seal.

+ EXTERIOR FITTINGS, REPAIRS,
Body quarter vent assembly - 3 door.
24.Remove rear damper.

+ REAR SUSPENSION, REPAIRS,
Damper.
25.Release vehicle harness from rear quarter and
position aside.
26. LH side: Remove tail door striker from 'E' post.
27. RH side: Remove tail door.

+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
28. RH side: Remove fuel filler neck.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Filler neck.
29. RH side: Remove fuel tank.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
2.Arrow A is shown to highlight the fact that there
are plug welds on the other side of the inner
wheel arch as well. These are to weld the rear
longitudinal to the inner wheel arch.
Refit
1. LH side: Fit tail door striker to 'E' post.
2. RH side: Fit fuel tank.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.
3. RH side: Fit fuel filler neck.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Filler neck.
4. RH side: Fit tail door.

+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
5.Secure vehicle harness to rear quarter.
6.Fit rear damper.

+ REAR SUSPENSION, REPAIRS,
Damper.
7.Fit seal and rear quarter vent.

+ EXTERIOR FITTINGS, REPAIRS,
Body quarter vent assembly - 3 door.
8.Fit headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.
9.Fit rear body side casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - body side - rear - 3
door.