battery LAND ROVER FREELANDER 2001 Workshop Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 2001, Model line: FREELANDER, Model: LAND ROVER FREELANDER 2001Pages: 1007, PDF Size: 23.47 MB
Page 809 of 1007
PANEL REPAIRS
77-2-54 REPAIRS
Outer rear wheel arch - 5 door
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 rear quarter lower casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
8.Remove rear seat.
+ SEATS, REPAIRS, Rear seat - LH.
+ SEATS, REPAIRS, Rear seat - RH.
9.Remove rear damper.
+ REAR SUSPENSION, REPAIRS,
Damper.
10. RH side: Remove fuel filler neck.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Filler neck.
11. 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. Refit
1. RH side: Fit fuel tank.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.
2. RH side: Fit fuel filler neck.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Filler neck.
3.Fit rear damper.
+ REAR SUSPENSION, REPAIRS,
Damper.
4.Fit rear seat.
+ SEATS, REPAIRS, Rear seat - LH.
+ SEATS, REPAIRS, Rear seat - RH.
5.Fit rear quarter lower casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
6.Fit rear wheel arch liner.
7.Fit rear bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
8.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
9.Connect all ECUs.
10.Connect alternator.
11.Connect battery earth lead.
Page 810 of 1007
PANEL REPAIRS
REPAIRS 77-2-55
Inner 'e' post - 3 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 soft/hard top.
9.Remove tail door aperture seal.
10.Remove rear quarter lower casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 3 door.
11.Remove loadspace carpet.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
12.Release vehicle harness from 'E' post and
position aside.
13. LH side: Remove tail door striker.
14. RH side: Remove tail door.
+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
15. RH side: Remove fuel filler neck.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Filler neck.
16. 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.
Page 811 of 1007
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.
Page 812 of 1007
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.
Page 813 of 1007
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.
Page 814 of 1007
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.
Page 815 of 1007
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.
Page 816 of 1007
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.
Page 817 of 1007
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.
Page 862 of 1007
CORROSION PREVENTION AND SEALING
LEAK DETECTION 77-4-31
LEAK DETECT ION
Water Leaks
Where water leakage is involved, always adopt a logical approach to the problem using a combination of skill,
experience and intuition. Do not reach a conclusion based only on visual evidence, such as assuming that a wet
footwell is caused by a leak emanating from the windscreen. It will often be found that the source of the leak is
elsewhere. Use of the correct procedure will increase the chance of locating a leak, however obscure it may seem.
Tools and equipment
The following tools and equipment are recommended for the purpose of detection and rectification of water leaks:
1Garden sprayer (hand-operated).
2Wet/dry vacuum cleaner.
3Dry, absorbent cloths.
4Battery torch.
5Small mirror.
6Weatherstrip locating tool.
7Trim panel remover.
8Small wooden or plastic wedges.
9Dry compressed air supply.
10Hot air blower.
11Sealer applicators.
12Ultrasonic leak detector.
During leak detection, the vehicle should be considered in three basic sections:
lThe front interior space.
lThe rear passenger space.
lThe loadspace or boot.
Testing
From the information supplied by the customer it should be possible for the bodyshop operator to locate the starting
point from which the leak may be detected. After the area of the leak has been identified, find the actual point of entry
into the vehicle.
A simple and effective means in the first instance is an ordinary garden spray with provision for pressure and jet
adjustment, which will allow water to be directed in a jet or turned into a fine spray. Use a mirror and a battery-powered
torch (NOT a mains voltage inspection lamp) to see into dark corners.
The sequence of testing is particularly important. Start at the lowest point and work slowly upwards, to avoid testing
in one area while masking the leak in another. For example, if testing started at the level of the windscreen, any water
cascading into the plenum chamber could leak through a bulkhead grommet and into the footwells. Even at this point
it could still be wrongly assumed that the windscreen seal was at fault.
Another important part of identifying a water leak is by visual examination of door aperture seals, grommets and
weatherstrips for damage, deterioration or misalignment, together with the fit of the door itself against the seals.
Sealing
When the point of the leak has been detected, it will then be necessary to rectify it using the following procedure:
1Renew all door aperture seals and weatherstrips which have suffered damage, misalignment or deterioration.
2Check all body seals to ensure that they are correctly located on their mounting flanges/faces using a lipping
tool if necessary.
3Dry out body seams to be treated using compressed air and/or a hot air blower as necessary.
4Apply sealant on the outside of the joint wherever possible to ensure the exclusion of water.
5When rectifying leaks between a screen glass and its weatherstrip (or in the case of direct glazing, between the
glass and bodywork), avoid removing the glass if possible. Apply the approved material at the appropriate
location (i.e. glass to weatherstrip or glass to body).