roof LAND ROVER FREELANDER 2001 Service Manual

PANEL REPAIRS
77-2-50 REPAIRS
10.Fit rear seat.

+ SEATS, REPAIRS, Rear seat - LH.

+ SEATS, REPAIRS, Rear seat - RH.
11.Fit loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
12.Fit rear side seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - rear - LH.
13.Fit rear quarter upper casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - upper
- 3 door.
14.Fit rear quarter lower casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 3 door.
15.Fit tail lamp.

+ LIGHTING, REPAIRS, Lamp
assembly - tail.
16.Fit rear roof panel finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Moulding - roof - 5 door.
17.Fit tail door aperture seal.
18.Fit soft/hard top.
19.Secure carpet to inner sill and rear heelboard.
20.Fit front door aperture seal.
21.Fit treadplate to front door aperture.
22.Fit door striker to 'B' post.
23.Fit rear wheel arch liner.
24.Fit rear bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
25.Fit sill lower finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Finisher - sill - lower.
26.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
27.Connect all ECUs.
28.Connect alternator.
29.Connect battery earth lead.
Complete rear quarter - 5 door
In this procedure, the rear outer body side panel is
replaced in conjunction with the complete rear
quarter.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove sill lower finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Finisher - sill - lower.
6.Remove rear bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
7.Remove rear wheel arch liner.
8.Remove rear door striker from 'D' post.
9.Remove treadplate from rear door aperture.
10.Remove rear door aperture seal.
11.Release carpet from inner sill and rear
heelboard and position aside.
12.Remove tail door glass upper finisher.
13.Remove tail door glass side finisher.

+ DOORS, REPAIRS, Finisher - rear
screen - side - 5 door.
14.Remove tail door aperture seal.
15.Remove roof panel finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Moulding - roof - 5 door.
16.Remove tail lamp.

+ LIGHTING, REPAIRS, Lamp
assembly - tail.
17.Remove rear quarter lower casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
18.Remove rear quarter upper casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - upper
- 5 door.
19.Remove rear side seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - rear - LH.
20.Remove loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
21.Remove rear seat.

+ SEATS, REPAIRS, Rear seat - LH.

+ SEATS, REPAIRS, Rear seat - RH.
22.Remove headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.

PANEL REPAIRS
77-2-52 REPAIRS
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.
2.Arrow A is shown to highlight the fact that there
are plug welds on the other side of the inner
wheel arch as well. These are to weld the rear
longitudinal to the inner wheel arch.
Refit
1. LH side: Fit tail door striker to 'E' post.
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 rear quarter.
6.Fit rear damper.

+ REAR SUSPENSION, REPAIRS,
Damper.
7.Fit rear body side glass.

+ SCREENS, REPAIRS, Glass - body
side - rear.
8.Fit headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.9.Fit rear seat.

+ SEATS, REPAIRS, Rear seat - LH.

+ SEATS, REPAIRS, Rear seat - RH.
10.Fit loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
11.Fit rear side seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - rear - LH.
12.Fit rear quarter upper casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - upper
- 5 door.
13.Fit rear quarter lower casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
14.Fit tail lamp.

+ LIGHTING, REPAIRS, Lamp
assembly - tail.
15.Fit roof panel finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Moulding - roof - 5 door.
16.Fit tail door aperture seal.
17.Fit tail door glass side finisher.

+ DOORS, REPAIRS, Finisher - rear
screen - side - 5 door.
18.Fit tail door glass upper finisher.
19.Secure carpet to inner sill and rear heelboard.
20.Fit rear door aperture seal.
21.Fit treadplate to rear door aperture.
22.Fit rear door striker to 'D' post.
23.Fit rear wheel arch liner.
24.Fit rear bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
25.Fit sill lower finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Finisher - sill - lower.
26.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
27.Connect all ECUs.
28.Connect alternator.
29.Connect battery earth lead.

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 77-2-61
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.

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.

PANEL REPAIRS
TIMES 77-2-63
TIME S
TIME SCHEDULES
The following information shows the total time taken to replace single panels and complete assemblies. This time
includes removal of Mechanical, Electrical and Trim (MET) items, plus paint times based on Metallic Clear Over Base
Paint.
The times shown were generated by Thatcham (the Motor Insurance Repair and Research Centre) and are to be used
as a guide only.
Panel/assembly panel replacement times 5 Door
Panel Description Total time
Body side LH 29.4
Body side RH 31.5
Bonnet 7.2
Bonnet locking platform 7.0
Door front - each 8.4
Door rear - each 8.1
Door skin front - each 12.2
Door skin rear - each 11.2
Front bulkhead assembly 12.7
Front lower crossmember 8.5
Headlamp mounting panel 6.4
Rear floor crossmember assembly 9.5
Roof assembly 23.5
Bodyside lower outer LH 16.8
Bodyside lower outer RH 16.9
Taildoor 9.0
Wing6.9
Bodyside rear outer LH 19.3
Bodyside rear outer RH 21.5

PANEL REPAIRS
77-2-66 TIMES
5 door - Rear end combination panel times
Panel/assembly replacement times 3 Door
Panel description Total time
Rear bumper
Rear outer bodyside panel
E-post inner assembly
Gusset rear floor
Crossmember assembly rear floor
31.2 LH
33.4 RH
Rear bumper
Rear outer bodyside panel LH & RH
E-post inner assembly LH & RH
Gusset rear floor LH & RH
Crossmember assembly rear floor
51.2
Rear bumper
Rear outer bodyside panel
E-post inner assembly
Quarter complete rear assembly
Gusset rear floor
Crossmember assembly rear floor
Longitudinal rear section
Rear floor panel
44.7 LH
46.8 RH
Rear bumper
Rear outer bodyside panel LH & RH
E-post inner assembly LH & RH
Quarter complete rear assembly LH & RH
Gusset rear floor LH & RH
Crossmember assembly rear floor
Longitudinal rear section LH & RH
Rear floor panel
69.2
Panel Description Total time
Body side LH 30.1
Body side RH 31.9
Door front - each 8.9
Door rear - each 8.1
Door skin front - each 12.9
Front bulkhead assembly 12.6
Crossmember assembly rear floor 12.1
Roof assembly 19.9
Bodyside lower outer LH 14
Bodyside lower outer RH 14.1
Bodyside rear outer LH 22.4
Bodyside rear outer RH 24.3

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
SEALING 77-4-17
Adhesive on roof - 5 door
Joints symmetrically opposite to those shown are also treated. Apply 3 mm diameter beads to all joints shown.
Seam Sealers
A heat cured, PVC based sealant is applied to specific joint seams during factory assembly. This material is not
suitable for service use and, during repair, should be substituted by an approved Seam Sealer.
Seams to which seam sealer is applied during factory assembly are detailed in the following Figures.
Apply seam sealers after the application of primer and before the application of surfacer and top coat. The seam
sealer must form a continuous bead, with the profile of the bead dependant on the type of seam. If seam sealer is
applied with a brush, take particular care to maintain the required coverage of the seam. Where shaping of the seam
sealer is required, use a cloth soaked with solvent such as white spirit or Shell SBP3 to achieve the required finish.
Ensure that ALL accessible repair seams are sealed following a repair. Damage to a vehicle often flexes areas of the
body remote from the impact. As a result, the seam sealer in these areas may be disturbed by subsequent
straightening and repair operations. Check all seams in the vicinity of the area undergoing repair for evidence of
cracked seam sealer, then clean out as required and apply fresh seam sealer using the following procedure:
lClean the affected seam and re-treat any exposed metal areas with a suitable etch phosphate primer.
lTreat affected area with an etch-acid primer.
lApply appropriate seam sealer as necessary.
lApply appropriate colour coat (and underbody sealer as applicable).
Where seams are inaccessible following the reassembly or fitting of components, ensure that a paste-type seam
sealer is applied to such seams. Certain seams also become inaccessible after the completion of panel repairs. In
such instances apply seam sealer and paint before final assembly.
Provided access is adequate, apply seam sealer to both sides of a repair joint. Where access is limited to one side
only (e.g. box sections), treat the affected box member with cavity wax.