LAND ROVER FREELANDER 2001 Workshop Manual

PANEL REPAIRS
77-2-56 REPAIRS
Refit
1. LH side: Fit tail door striker.
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 'E' post.
6.Fit loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
7.Fit rear quarter lower casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 3 door.
8.Fit tail door aperture seal.
9.Fit soft/hard top.
10.Fit tail lamp.

+ LIGHTING, REPAIRS, Lamp
assembly - tail.
11.Fit rear wheel arch liner.
12.Fit rear bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
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.
Inner 'e' post - 5 door
In this procedure, the rear outer body side panel and
the rear body side reinforcement assembly is
replaced in conjunction with the inner 'E' post
assembly.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove rear bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
6.Remove rear wheel arch liner.
7.Remove tail lamp.

+ LIGHTING, REPAIRS, Lamp
assembly - tail.
8.Remove roof panel finisher.

+ DOORS, REPAIRS, Finisher - rear
screen - side - 5 door.
9.Remove tail door glass upper finisher.
10.Remove tail door glass side finisher.

+ DOORS, REPAIRS, Finisher - rear
screen - side - 5 door.
11.Remove tail door aperture seal.
12.Remove rear quarter lower casing.

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

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - upper
- 5 door.
14.Remove loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
15.Remove rear body side glass.

+ SCREENS, REPAIRS, Glass - body
side - rear.
16.Release vehicle harness from 'E' post and
position aside.
17. LH side: Remove tail door striker.
18. RH side: Remove tail door.

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

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

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.

PANEL REPAIRS
REPAIRS 77-2-57
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 tail door striker.
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 'E' post.
6.Fit rear body side glass.

+ SCREENS, REPAIRS, Glass - body
side - rear.
7.Fit loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
8.Fit rear quarter upper casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - upper
- 5 door.
9.Fit rear quarter lower casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
10.Fit tail door aperture seal.
11.Fit tail door glass side finisher.

+ DOORS, REPAIRS, Finisher - rear
screen - side - 5 door.
12.Fit tail door glass upper finisher.
13.Fit roof panel finisher.

+ DOORS, REPAIRS, Finisher - rear
screen - side - 5 door.
14.Fit tail lamp.

+ LIGHTING, REPAIRS, Lamp
assembly - tail.
15.Fit rear wheel arch liner.
16.Fit rear bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
17.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
18.Connect all ECUs.
19.Connect alternator.
20.Connect battery earth lead.

PANEL REPAIRS
77-2-58 REPAIRS
Rear floor crossmember assembly
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove tail door.

+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
5.Remove tail door aperture seal.
6.Remove LH and RH rear quarter lower casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
7.Remove loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
8.Release vehicle harness from rear body lower
closing and position aside.
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.Secure vehicle harness to rear body lower
closing.
2.Fit loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
3.Fit LH and RH rear quarter lower casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
4.Fit tail door aperture seal.
5.Fit tail door.

+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
6.Connect all ECUs.
7.Connect alternator.
8.Connect battery earth lead.

PANEL REPAIRS
REPAIRS 77-2-59
Rear floor
In this procedure, the inner quarter to rear floor
gussets are replaced in conjunction with the rear
floor. If required, the safe well can be replaced
separately.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove tail exhaust pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - tail.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES 1.8, REPAIRS, Exhaust pipe -
tail.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Tail pipe &
silencer.
5.Remove tail door.

+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
6.Remove tail door aperture seal.
7.Remove LH and RH rear quarter lower casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
8.Remove loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
9.Remove fuel tank.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.
10.Release vehicle harness from rear body lower
closing and position aside. 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.Secure vehicle harness to rear body lower
closing.
2.Fit fuel tank.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.
3.Fit loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
4.Fit LH and RH rear quarter lower casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
5.Fit tail door aperture seal.
6.Fit tail door.

+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
7.Fit tail exhaust pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - tail.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES 1.8, REPAIRS, Exhaust pipe -
tail.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Tail pipe &
silencer.
8.Connect all ECUs.
9.Connect alternator.
10.Connect battery earth lead.

PANEL REPAIRS
77-2-60 REPAIRS
Floor longitudinal
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove tail exhaust pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - tail.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES 1.8, REPAIRS, Exhaust pipe -
tail.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Tail pipe &
silencer.
5.Remove tail door.

+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
6.Remove tail door aperture seal.
7.Remove LH and RH rear quarter lower casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
8.Remove loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
9.Remove fuel tank.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.
10.Release vehicle harness from rear body lower
closing and position aside. 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.Secure vehicle harness to rear body lower
closing.
2.Fit fuel tank.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.
3.Fit loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
4.Fit LH and RH rear quarter lower casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
5.Fit tail door aperture seal.
6.Fit tail door.

+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
7.Fit tail exhaust pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - tail.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES 1.8, REPAIRS, Exhaust pipe -
tail.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Tail pipe &
silencer.
8.Connect all ECUs.
9.Connect alternator.
10.Connect battery earth lead.

PANEL REPAIRS
REPAIRS 77-2-61
Front roof assembly - 3 door
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove LH and RH front roof panel finishers.
5.Remove headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.
6.Remove sunroof assembly.

+ SUNROOF, REPAIRS, Sun/sliding
roof - complete - front - 3 door.
7.Remove windscreen.

+ SCREENS, REPAIRS, Windscreen.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. There are
no plug welds used in this procedure, spot
welds only.
Refit
1.Fit windscreen.

+ SCREENS, REPAIRS, Windscreen.
2.Fit sunroof.

+ SUNROOF, REPAIRS, Sun/sliding
roof - complete - front - 3 door.
3.Fit headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.
4.Fit LH and RH front roof panel finishers.
5.Connect all ECUs.
6.Connect alternator.
7.Connect battery earth lead.
Rear roof assembly - 3 door
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove soft/hard top.
5.Remove LH and RH rear roof panel finishers.
6.Remove headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.
7.Remove sunroof.

+ SUNROOF, REPAIRS, Sun/sliding
roof - complete - front - 3 door.
8.Remove aerial.

+ IN CAR ENTERTAINMENT,
REPAIRS, Aerial - manual - 3 door.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. There are
no plug welds used in this procedure, spot
welds only.
Refit
1.Fit aerial.

+ IN CAR ENTERTAINMENT,
REPAIRS, Aerial - manual - 3 door.
2.Fit sunroof.

+ SUNROOF, REPAIRS, Sun/sliding
roof - complete - front - 3 door.
3.Fit headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.
4.Fit LH and RH rear roof panel finishers.
5.Fit soft/hard top.
6.Connect all ECUs.
7.Connect alternator.
8.Connect battery earth lead.

Roof assembly - 5 door
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove tail door glass upper finisher.
5.Remove LH and RH roof panel finishers.

+ EXTERIOR FITTINGS, REPAIRS,
Moulding - roof - 5 door.
6.Remove headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
7.If applicable, remove sunroof.

+ SUNROOF, REPAIRS, Sun/sliding
roof - complete - front - 5 door.
8.Remove aerial.

+ IN CAR ENTERTAINMENT,
REPAIRS, Aerial - manual - 5 door.
9.Remove windscreen.

+ SCREENS, REPAIRS, Windscreen.
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 windscreen.

+ SCREENS, REPAIRS, Windscreen.
2.Fit aerial.

+ IN CAR ENTERTAINMENT,
REPAIRS, Aerial - manual - 5 door.
3.If applicable, fit sunroof.

+ SUNROOF, REPAIRS, Sun/sliding
roof - complete - front - 5 door.
4.Fit headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
5.Fit LH and RH roof panel finishers.

+ EXTERIOR FITTINGS, REPAIRS,
Moulding - roof - 5 door.
6.Fit tail door glass upper finisher.
7.Connect all ECUs.
8.Connect alternator.
9.Connect battery earth lead.

PANEL REPAIRS
TIMES 77-2-63
TIME S
TIME SCHEDULES
The following information shows the total time taken to replace single panels and complete assemblies. This time
includes removal of Mechanical, Electrical and Trim (MET) items, plus paint times based on Metallic Clear Over Base
Paint.
The times shown were generated by Thatcham (the Motor Insurance Repair and Research Centre) and are to be used
as a guide only.
Panel/assembly panel replacement times 5 Door
Panel Description Total time
Body side LH 29.4
Body side RH 31.5
Bonnet 7.2
Bonnet locking platform 7.0
Door front - each 8.4
Door rear - each 8.1
Door skin front - each 12.2
Door skin rear - each 11.2
Front bulkhead assembly 12.7
Front lower crossmember 8.5
Headlamp mounting panel 6.4
Rear floor crossmember assembly 9.5
Roof assembly 23.5
Bodyside lower outer LH 16.8
Bodyside lower outer RH 16.9
Taildoor 9.0
Wing6.9
Bodyside rear outer LH 19.3
Bodyside rear outer RH 21.5

PANEL REPAIRS
77-2-64 TIMES
Combination panel replacement times
The following panel combination times show the total time to remove/refit body panels, MET items and any paint
processes.
5 Door - Front end combination panel times
Panel Description Total Time
Bonnet locking platform
Bumper front
Headlamp mounting panel
Wing
15.3
Bumper front
Front Panel assembly
Wing RH & LH
20.6
Bonnet locking platform
Bumper front
Sidemember closing panel
Sidemember front section
Front crossmember lower
Headlamp mounting panel
Wing
Valance upper assembly section
Valance outer reinforcement section
35.7 LH
37.9 RH
Bumper front
Sidemember closing panel LH front
Sidemember closing panel RH front
Sidemember complete assembly LH
Sidemember complete assembly RH
Front bulkhead assembly
Wing LH & RH
Valance upper assembly LH & RH
Valance outer reinforcement section LH & RH
49.1
Bonnet locking platform
Bumper front
Sidemember closing panel section
Sidemember front section
Front crossmember lower
Headlamp mounting panel
Valance front section
Wing
Valance upper assembly section
Valance outer reinforcement section
27.1 LH
27.7 RH

PANEL REPAIRS
TIMES 77-2-65
5 door - Bodyside combination panel times
Panel description Total time
Front door
Wing
11.6
Rear door
Rear outer bodyside panel
23.4 LH
25.7 RH
Front door
Rear door
Lower outer bodyside panel
26.1 LH
26.2 RH
Front door
Rear door
Bodyside assembly
Wing
40.5 LH
42.9 RH
Front door
Front outer bodyside panel
A-post reinforcement
Windscreen
Wing
Valance outer reinforcement rear section
34.1 LH
35.5 RH