length LAND ROVER FREELANDER 2001 Owner's Guide

BODY DIMENSIONS
77-1-14 BODY DIMENSIONS
Rear end information
Item From To Length
A Waist rail reinforcement Rear header 975.3 (38.397)
B Rear bodyside `LH` Rear bodyside `RH` 1258.1 (49.531)

BODY DIMENSIONS
BODY DIMENSIONS 77-1-15
Rear floor information
Item From To Length
A Front seat, rear mounting hole Spring location, rear fixing hole 1350 (53.149)
B Front seat, rear mounting hole `LH` Front seat, rear mounting hole `RH` 1298 (51.102)
C Spring location, rear fixing hole `LH` Spring location, rear fixing hole `RH` 1220 (48.031)
D Front seat, rear mounting hole `LH` Front seat, rear mounting hole `RH` 1846 (72.677)

PANEL REPAIRS
77-2-16 WELDING PROCEDURES
General Welding Precautions
General
For ease of reference, the diagrams on the following pages show only the type of weld used in repair where it varies
from that used in production.
The replacement welds in the welding diagrams are denoted by the following symbols:
a = Single/Multiple thickness plug welds
b = MIG seam weld
When carrying out welding operations the following criteria must be observed:
lWhere resistance spot welds have been used in production, these must be reproduced with new spot welds in
replacement where possible. All such reproduction spot welds must be spaced 30 mm (1.181) apart;
lWhen spot welding, it is recommended that test coupons of the same metal gauges and materials are produced
to carry out peel tests to ensure that welding equipment being used can produce a satisfactory joint. Plug welds
must be used if a satisfactory spot weld cannot be produced;
lThe electrode arms on hand-held spot welding guns must not exceed 300 mm (11.811) in length;
lSingle-side spot welding is not acceptable;
lBrazing and gas welding are not acceptable EXCEPT where they have been specified in production;
lWhere 3 metal thicknesses or more are to be welded together it is imperative to use MIG plug welds to ensure
joint strength;
lMIG plug welds must be used in repair joints where there is no access for a resistance spot welder. To replace
each production spot weld, an 8 mm (0.314) approx hole must be drilled and/or punched, and a MIG plug weld
then made in its place. The number of plug welds must match exactly the number of spot welds which have been
removed;
lWhere holes are left in an existing panel after removal of the spot welds, a single MIG plug weld will be made in
each hole as appropriate.
Electronic Control Units
The electronic control units (ECU) fitted to vehicles make it advisable to follow suitable precautions prior to carrying
out welding repair operations. Harsh conditions of heat and vibration may be generated during these operations which
could cause damage to the units.
In particular, it is essential to follow the appropriate precautions when disconnecting or removing the airbag DCU.
Equipment
Prior to commencing any test procedure on the vehicle, ensure that the relevant test equipment is working correctly
and any harness or connectors are in good condition. This particularly applies to electronic control units.

PANEL REPAIRS
77-2-22 PROCEDURES
5.Apply adhesive sealant to panel joint surfaces.
Offer up and align
1.Offer up new panel and align with associated
panels. Clamp into position using welding
clamps or Mole grips. Where a joggle or brace
joint is being adopted, make a set in the original
panel joint edge or insert a brace behind the
joint.
NOTE: In cases where access for welding
clamps is difficult, it may be necessary to use
tack welds.Welding
1.Select arms for resistance spot welding and
shape electrode tips using a tip trimmer. Tips
should be dressed so the diameter is equal to
twice the thickness of the metal to be welded
plus 3.0 mm (0.118 ins).
CAUTION: Use arms not exceeding 300 mm
(11.811ins) in length.
NOTE: To maintain weld efficiency, the tips will
require regular cleaning and dressing.
2.Fit resistance spot welding arms and test
equipment for satisfactory operation, using test
coupons. Where monitoring equipment is not
available, verify weld strength by checking that
metal around the weld puddle pulls apart under
tension during pulling.

BODY SEALING MATERIALS
77-3-6 APPLICATION EQUIPMENT
Cooper Pegler Falcon Junior Pneumatic Gun (Airless)
Intended primarily for applying transit wax, this pneumatic sprayer has a 5-litre container with integral hand pump and
provides an effective means of wax spraying without the need for compressed air or additional services.
A selection of nozzles, lances, hose lengths and a trigger valve assembly with integral filter allows flexibility in use.
Additional applications include general maintenance, wax injection and paint application. Heavy-bodied materials
may also be applied. All parts are fully replaceable and a wide range of nozzle configurations is available.
SATA Schutz Gun Model UBE
The SATA Schutz Gun is approved for the retreatment of vehicle underbody areas with protective coatings as
supplied in 1 litre, purpose-designed 'one-way' containers. The screw thread fitting (female on the gun) is standard
to most Schutz-type packs.
Full operating details are supplied with the equipment.
SATA HKD1 Wax Injection Injection Equipment
This equipment is approved for carrying out cavity wax re-treatment. The SATA HKD1 set comprises a high quality
forged gun with 1-litre pressure feed container, a flexible nylon lance, a straight 1100mm steel lance and hooked-
wand lance. A quick-change coupling is provided as a standard fitting to allow lances to be easily interchanged. Each
lance has an integral, machined nozzle with specialised spray characteristics to suit the type of box section to be
treated.

CORROSION PREVENTION AND SEALING
77-4-24 SEALING
Sealed seams in front wheelarch, engine compartment and screen rail
Seams symmetrically opposite to those shown are also treated. Use putty on seams marked 'A'. On windscreen rail,
sealant to be finished flush to adjacent surfaces over length 'B'. On front suspension turrets, ensure damper mounting
holes are kept free of sealant.

CORROSION PREVENTION AND SEALING
SEALING 77-4-25
Seam sealer on vehicle interior and rear quarter - 3 door
Seams symmetrically opposite to those shown are also treated. Sealant to be wiped to a smooth finish over length 'A'
(rear load floor to rear heelboard underframe).

CORROSION PREVENTION AND SEALING
77-4-26 SEALING
Seam sealer on vehicle interior and rear quarter - 5 door
Seams symmetrically opposite to those shown are also treated. Sealant to be wiped to a smooth finish over length 'A'
(rear load floor to rear heelboard underframe).

AIR CONDITIONING
REPAIRS 82-11
11.Remove 2 bolts securing A/C pipes to
condenser and release pipes from condenser.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
12.Remove and discard 'O' rings from A/C pipes.
13.Remove condenser.
14.Remove 8 screws, securing 4 mounting
brackets to condenser and move aside.
15.Remove and discard receiver drier, plug
connections.Refit
1.Fit condenser mounting brackets, fully tighten
LH screws. Leave RH screws loose until
receiver drier is fitted.
CAUTION: Ensure that bolts of the correct
length are used on refit.
2.Lubricate new 'O' rings with clean refrigerant
oil, fit one seal to each condenser pipe.
3.Position A/C pipes to condenser, fit bolts and
tighten to 8 Nm (6 lbf.ft).
4.Fit bolts securing condenser to radiator and
tighten to 8 Nm (6 lbf.ft).
5.Fit receiver drier assembly to condenser.

+ AIR CONDITIONING, REPAIRS,
Receiver drier.
6.Fit air deflectors and secure with scrivets.
7. Up to 04MY: Position armature, fit and tighten
4 nuts and bolts securing armature to body to
25 Nm (18 lbf.ft).
8. 04MY on: Position armature, fit bolts securing
armature to crash cans and tighten to 25 Nm
(18 lbf.ft).
9. KV6 models:Align PAS fluid cooler and tighten
bolts to 8 Nm (6 lbf.ft).
10.Fit bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
11. Td4 models: Fit intercooler.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Intercooler.
12.Recharge A/C system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery -
recycling and recharge.
13.Connect battery earth lead.
M82 0706

CHARGING AND STARTING
86-1-2 ADJUSTMENTS
Ancillary drive belt - K1.8 with A/C
$% 86.10.05
Check
1.Disconnect battery earth lead.
2.Turn steering on RH lock.
3.Remove 3 bolts and remove splash shield.
4.Rotate crankshaft a sufficient number of turns
to check condition of drive belt. Renew a drive
belt that shows signs of wear, splitting or oil
contamination.
5.Check belt length, belt must be renewed before
indicator reaches RH end of slot.
6.Fit splash shield and secure with bolts.
7.Straighten steering.
8.Connect battery earth lead.