ECU 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 733 of 1007
HOOD
76-7-8 REPAIRS
Catch and retainer - hard-back - front
$% 76.61.94
Remove
1.Remove hard-back.
+ HOOD, REPAIRS, Frame & hood
cover - assembly - remove for access & refit.
2.Remove 2 Torx screws securing catch, slide
catch from position and remove catch. 3.Remove Torx screw securing roof finisher to
hard-back retainer.
4.Remove 3 Torx screws securing hard-back
retainer and remove retainer.
Refit
1.Position hard-back retainer, fit Torx screws
and tighten to 10Nm (7.5 lbf.ft).
2.Fit Torx screw securing roof finisher.
3.Position catch, fit Torx screws and tighten to 10
Nm (7.5 lbf.ft).
Ensure formed washer is correctly located
in catch recess.
4.Fit hard-back.
+ HOOD, REPAIRS, Frame & hood
cover - assembly - remove for access & refit.
Page 734 of 1007
HOOD
REPAIRS 76-7-9
Catch and retainer - hard-back - rear
$% 76.61.95
Remove
1.Remove hard-back or soft-back.
+ HOOD, REPAIRS, Hard top - remove
for access & refit.
+ HOOD, REPAIRS, Hard top - remove
for access & refit.
2.Remove 2 screws securing 'E' post finisher,
release finisher from 2 clips and remove
finisher.
3.Remove 3 Torx screws securing catch and
remove catch.
4.Remove lower rear quarter trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 3 door.5.Remove 3 Torx screws securing hard-back
retainer and remove retainer.
Refit
1.Position catch, fit Torx screws and tighten to
10Nm (7.5 lbf.ft).
2.Position 'E' post finisher, engage in clips and
secure with screws.
3.Position hard-back retainer, fit Torx screws
and tighten to 10 Nm (7.5 lbf.ft).
4.Fit lower rear quarter trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 3 door.
5.Fit hard-back or soft-back.
+ HOOD, REPAIRS, Hard top - remove
for access & refit.
+ HOOD, REPAIRS, Frame & hood
cover - assembly - remove for access & refit.
Page 770 of 1007
PANEL REPAIRS
WELDING PROCEDURES 77-2-15
WE LDING PROCEDURE S
ECU locations (3 door model shown, 5
door model similar)
1Central control unit (on forward side of
passenger compartment fusebox, behind
driver's glove box)
2RF Receiver (on top of instrument pack)
3Immobiliser ECU (rear of fascia)
4DCU (SRS on transmission tunnel below
heater)
5EAT ECU (inside Environmental 'E' box)
6ECM (inside 'E' box)
7Fuel Burning Heater (behind wheelarch liner)
'Diesel only'8Cooling Fan Ecu (rear of radiator housing) all
models except 1.8
9ABS ECU (RH side front of engine
compartment)
10Folding door mirror ECU (on transmission
tunnel under centre console)
11Window lift ECU (on driver `A` post)
12Cruise Control Interface ECU (under R/H seat)
13Cruise control ECU (under R/H seat)
Page 771 of 1007
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.
Page 780 of 1007
PANEL REPAIRS
REPAIRS 77-2-25
REPAIRS
Front bulkhead assembly
In this procedure, the crossmember gusset plates
are replaced in conjunction with the front bulkhead
assembly.
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 PAS fluid cooler.
+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
8.Remove LH and RH headlamps.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
9.Release wiring to headlamps and position
aside.
10.Remove LH and RH engine bay shields.
11.Remove bumper valance LH and RH
attachment brackets.
12.Remove battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
13.Remove air intake hose.
14.Remove horn.
+ SECURITY, REPAIRS, Horn.
15.Remove windscreen washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
16.Remove bonnet lock.
17.Support bonnet in open position.
18.Remove bonnet stay. 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 781 of 1007
PANEL REPAIRS
77-2-26 REPAIRS
Refit
1.Fit bonnet stay.
2.Fit bonnet lock.
3.Fit windscreen washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
4.Fit horn.
+ SECURITY, REPAIRS, Horn.
5.Fit air intake hose.
6.Fit battery. Do not connect earth lead.
+ CHARGING AND STARTING,
REPAIRS, Battery.
7.Fit bumper valance LH and RH attachment
brackets.
8.Fit LH and RH engine bay shields.
9.Fit LH and RH headlamps.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY. Secure headlamps
wiring.
10.Fit PAS fluid cooler.
+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
11.Fit radiator.
+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
12.Fit front bumper armature.
13.Fit front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
14.Connect all ECUs.
15.Connect alternator.
16.Connect battery earth lead.
Page 782 of 1007
PANEL REPAIRS
REPAIRS 77-2-27
Bonnet locking platform
In this procedure the bonnet locking platform
reinforcement is also replaced in conjunction with the
bonnet locking platform.
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 radiator.
+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
6.Remove both headlamp assemblies.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
7.Remove horn.
+ SECURITY, REPAIRS, Horn.
8.Remove battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
9.Remove air intake hose.
10.Remove bonnet lock.
11.Support bonnet in open position.
12.Remove bonnet stay.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Refit
1.Fit bonnet stay.
2.Fit bonnet lock.
3.Fit air intake hose.
4.Fit battery. Do not connect earth lead.
+ CHARGING AND STARTING,
REPAIRS, Battery.
5.Fit horn.
+ SECURITY, REPAIRS, Horn.
6.Fit both headlamp assemblies.
+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
7.Fit radiator.
+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
8.Fit front bumper valance.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
9.Connect all ECUs.
10.Connect alternator.
11.Connect battery earth lead.
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.