fuel 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
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.

CORROSION PREVENTION AND SEALING
SEALING 77-4-9
Inspections during maintenance servicing
It is a requirement of the Corrosion Warranty that the vehicle body is checked for corrosion by an authorised Land
Rover Dealer at least once a year, to ensure that the factory-applied protection remains effective.
Service Job Sheets include the following operations to check bodywork for corrosion:
lWith the vehicle on a lift, carry out visual check of underbody sealer for damage.
lWith the vehicle lowered, inspect exterior paintwork for damage and body panels for corrosion.
The vehicle must be washed and free from deposits prior to inspection. It is part of the owner's responsibility to ensure
that the vehicle is kept free of accumulations of mud which could accelerate the onset of corrosion. It will be necessary
for the vehicle to be washed by the Dealer prior to inspection of bodywork if the customer has offered the vehicle in
a dirty condition. Particular attention should be paid to areas where access is difficult.
The checks described above are intended to be visual only. It is not intended that the operator should remove trim
panels, finishers, rubbing strips or sound-deadening materials when checking the vehicle for corrosion and paint
damage.
With the vehicle on a lift, and using an inspection or spot lamp, visually check for the following:
lCorrosion damage and damaged paintwork, condition of underbody sealer on front and rear lower panels, sills
and wheel arches.
lDamage to underbody sealer. Corrosion in areas adjacent to suspension mountings and fuel tank fixings.
The presence of small blisters in underbody sealer is acceptable, providing they do not expose bare metal.
Pay special attention to signs of damage caused to panels or corrosion protection material by incorrect jack
positioning.
caut : It is essential to follow the correct jacking and lifting procedures.
With the vehicle lowered, visually check for evidence of damage and corrosion on all visible painted areas, in
particular the following:
lFront edge of bonnet.
lVisible flanges in engine compartment.
lLower body and door panels.
Rectify any bodywork damage or evidence of corrosion found during inspection as soon as is practicable, both to
minimise the extent of the damage and to ensure the long term effectiveness of the factory-applied corrosion
prevention treatment. Where the cost of rectification work is the owner's responsibility, the Dealer must advise the
owner and endorse the relevant documentation accordingly.
Where corrosion has become evident and is emanating from beneath a removable component (e.g. trim panel,
window glass, seat etc.), remove the component as required to permit effective rectification.

CORROSION PREVENTION AND SEALING
SEALING 77-4-15
Adhesive on body side and roof - 3 door
Joints symmetrically opposite to those shown are also treated. Apply 3 mm diameter beads except where detailed
otherwise (below).
1Apply 4 x 10 mm diameter spots
2Apply 3 x 4 mm diameter beads
3Apply 3 x 10 mm diameter spots
4Apply 6 mm diameter bead (fuel resistant seam sealer)

CORROSION PREVENTION AND SEALING
77-4-16 SEALING
Adhesive on body side - 5 door
Joints symmetrically opposite to those shown are also treated. Apply 3 mm diameter beads except where detailed
otherwise (below).
1Apply 4 x 10 mm diameter spots
2Apply 3 x 4 mm diameter beads
3Apply 3 x 10 mm diameter spots
4Apply 4 x 10 mm diameter spots
5Apply 3 x 4 mm diameter beads
6Apply 3 x 10 mm diameter spots
7Apply 6 mm diameter bead (fuel resistant seam sealer)

CORROSION PREVENTION AND SEALING
77-4-22 SEALING
Seam sealer on fuel filler and roof - 3 door
Seams symmetrically opposite to those shown are also treated. On roof seams, sealant to be finished flush to surface
forward of points 'A' and rearward of points 'B'.

CORROSION PREVENTION AND SEALING
SEALING 77-4-23
Seam sealer on fuel filler and roof - 5 door
Seams symmetrically opposite to those shown are also treated. On roof seam, sealant to be finished flush to surface
forward of point 'A'.

HEATING AND VENTILATION
80-18REPAIRS
Fuel burning heater (FBH)
$% 80.40.01
Remove
1.Disconnect battery earth lead.
2.Remove front bumper.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
3.Drain coolant.

+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.
4.Position container to collect coolant spillage.
5.Release clips, disconnect coolant feed and
return hoses from FBH.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
6.Position an absorbent cloth, release clip and
remove fuel feed hose from FBH. Plug
connections and move aside.7.Loosen 1 bolt and remove other bolt securing
FBH mounting bracket to body.
8.Release FBH from mounting, disconnect
multiplugs and move assembly aside.
NOTE: Do not carry out further dismantling if
component is removed for access only.
9.Remove 3 bolts securing FBH to mounting
bracket.
10.Remove bracket.
M80 0496
M80 0499