alternator LAND ROVER FREELANDER 2001 Owner's 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 783 of 1007
PANEL REPAIRS
77-2-28 REPAIRS
Headlamp mounting panel
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5.Remove front bumper armature.
6.Remove radiator.
+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
7.Remove headlamp assembly.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
8.Release wiring to headlamp and position aside.
9. LH side: Remove front bumper LH support
bracket.
10. LH side: Remove battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
11. LH side: Remove horn.
+ SECURITY, REPAIRS, Horn.
12. LH side: Remove air intake hose.
13. RH side: Remove front bumper RH support
bracket.
14. RH side: Remove windscreen washer
reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
15. 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.
Refit
1. LH side: Fit air intake hose.
2. LH side: Fit horn.
3. LH side: Fit battery. Do not connect earth lead.
+ CHARGING AND STARTING,
REPAIRS, Battery.
4. LH side: Fit front bumper LH support bracket.
5. RH side: Fit PAS fluid cooler.
+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
6. RH side: Fit windscreen washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
7. RH side: Fit front bumper LH support bracket.
8.Fit headlamp assembly.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.Secure headlamp
wiring.
9.Fit radiator.
+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
10.Fit front bumper armature.
11.Fit front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
12.Connect all ECUs.
13.Connect alternator.
14.Connect battery earth lead.
Page 784 of 1007
PANEL REPAIRS
REPAIRS 77-2-29
Front lower crossmember
In this procedure, the crossmember gusset plates
are replaced in conjunction with the front lower
crossmember.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove LH and RH engine bay shields.
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.Release wiring for LH and RH headlamps and
position aside.
Repair1.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. The front lower crossmember assembly
is only supplied with a limited amount of
spotwelds. Ensure that the correct amount of
plug welds are put onto the assembly as a
substitute for the spotwelds, see illustration
below.
Refit
1.Secure wiring to LH and RH headlamps.
2.Fit PAS fluid cooler.
+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
3.Fit radiator.
+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
4.Fit front bumper armature.
5.Fit front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
6.Fit LH and RH engine bay shields.
7.Connect all ECUs.
8.Connect alternator.
9.Connect battery earth lead.
Page 785 of 1007
PANEL REPAIRS
77-2-30 REPAIRS
Front sidemember (complete)
In this procedure, 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 alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
6.Remove front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
7.Remove front bumper armature.
8.Remove radiator.
+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
9.Remove PAS fluid cooler.
+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
10.Remove headlamp.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
11.Release wiring to headlamp and position aside.
12.Remove engine bay shield.
13.Remove front wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
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 PAS rack.
+ STEERING, REPAIRS, Power
steering rack.
17.Remove fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
18. LH side: Remove front bumper LH support
bracket.
19. LH side: Remove LH engine mounting from
body.
20. LH side: Remove battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
21. LH side: Remove air intake hose.
22. LH side: Remove horn.
+ SECURITY, REPAIRS, Horn.
23. RH side: Remove front bumper RH support
bracket.24. RH side: Remove RH engine mounting from
body.
25. RH side: Remove windscreen washer
reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
26. Driver's side: Remove passenger
compartment fuse box.
27. Driver's side: Remove brake pedal box and
brake servo.
28. Driver's side: Remove clutch pedal box.
29.Remove treadplate from front door aperture.
Release front carpet and position aside.
30.Remove insulation pads from engine bulkhead.
Page 786 of 1007
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.
Page 787 of 1007
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.
Page 788 of 1007
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.
Page 791 of 1007
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.
Page 792 of 1007
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.
Page 793 of 1007
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.
Page 794 of 1007
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.