suspension LAND ROVER FREELANDER 2001 Repair 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 545 of 1007
REAR SUSPENSION
64-10 REPAIRS
Link - adjustable - transverse
$% 64.35.70
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove road wheel.
3.Remove nut, bolt and washers securing
transverse links to hub.
4.Remove nut and bolt securing adjustable
transverse link to subframe. Collect dynamic
damper.
5.Remove transverse link.Refit
1.Fit transverse link.
2.Fit nuts, bolts, dynamic damper and washers
securing transverse link to hub and subframe
but do not tighten at this stage.
NOTE: Ensure that washers are fitted to both
ends of bolts
3.Support weight of vehicle with jack under rear
hub.
CAUTION: Nuts and bolts must be tightened
with weight of vehicle on suspension.
4.Tighten nuts and bolts to 105 Nm (77 lbf.ft).
5.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
6.Remove stands and lower vehicle.
7.Check and if necessary adjust rear wheel
alignment.
Page 546 of 1007
REAR SUSPENSION
REPAIRS 64-11
Link - transverse fixed
$% 64.35.72
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove road wheel.
3.Remove nut and bolt securing transverse link to
hub.
4.Remove nut and bolt securing fixed transverse
link to subframe.
5.Remove transverse link.Refit
1.Fit transverse link.
2.Fit nuts, bolts and washers securing transverse
link to hub and subframe but do not tighten at
this stage.
3.Support weight of vehicle with jack under rear
hub.
CAUTION: Nuts and bolts must be tightened
with the weight of the vehicle on the
suspension.
4.Tighten nuts and bolts to 105 Nm (77 lbf.ft).
5.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
6.Remove stands and lower vehicle.
7.Check and if necessary adjust rear wheel
alignment.
Page 547 of 1007
REAR SUSPENSION
64-12 REPAIRS
Bush - link - transverse
$% 64.35.76
Remove
1.Remove transverse link.
+ REAR SUSPENSION, REPAIRS, Link
- transverse fixed.
2.Note and mark bush orientation.
3. Large bush: Use LRT-60-008 to remove bush.4. Small bush: Use LRT-60-013 to remove bush.
Refit
1.Ensure bush bore is clean.
2.Ensure bush is correctly aligned.
3.Using LRT- 60-008 or LRT-60-013 fit new
bush.
4.Fit transverse link.
+ REAR SUSPENSION, REPAIRS, Link
- transverse fixed.
Page 548 of 1007
REAR SUSPENSION
REPAIRS 64-13
Sub frame
$% 64.35.78
Remove
1.Remove both drive shafts.
+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - LH.
+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - RH.
2.Reference mark rear propeller shaft for
reassembly.
3.Remove 4 nuts and bolts securing propeller
shaft to differential. Release propeller shaft and
tie aside.
4.Depress red locking collar and disconnect
breather pipe from differential casing.
5.Support the weight of the subframe assembly
on a jack.6.Remove 2 bolts securing handbrake cable clips
to subframe.
7.Remove 4 bolts securing subframe to body.
8.With assistance lower jack, manoeuvre
subframe around exhaust and remove from
vehicle.
NOTE: Do not carry out further dismantling if
component is removed for access only.
9.Remove 3 bolts securing differential mountings
to subframe and remove differential assembly.
Page 549 of 1007
REAR SUSPENSION
64-14 REPAIRS
10.Loosen 6 bolts securing mountings to
differential casing.Refit
1.Position centralising jig LRT-51-013 to align
differential assembly.
2.Fit differential assembly.
3.Fit bolts securing differential mountings to
subframe and tighten to 120 Nm (89 lbf.ft).
4.Tighten forward bolts to 65 Nm (48 lbf.ft).
5.Tighten rearward bolts to 65 Nm (48 lbf.ft).
6.Remove LRT-51-013.
7.With assistance position subframe assembly to
body and locate on dowels.
8.Fit subframe bolts and tighten to 190 Nm (140
lbf.ft).
9.Align handbrake cables, fit bolts and tighten to
22 Nm (16 lbf.ft).
10.Connect breather pipe.
11.Position propeller shaft to rear axle and align
reference marks.
12.Fit nuts and bolts securing propeller shaft to
rear axle and tighten to 65 Nm (48 lbf.ft).
13.Fit drive shafts.
+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - LH.
+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - RH.
14.Check and if necessary, adjust wheel
alignment.
Page 578 of 1007
BRAKES
REPAIRS 70-29
Sensor & harness - rear wheel
$% 70.65.31
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove road wheel.
3.Release ABS sensor multiplug from body clip
and disconnect multiplug.
4.Release ABS sensor harness from 3 grommets
on suspension and body brackets.
5.Release harness from clip on rear brake hose.6.Remove bolt securing ABS sensor to hub, if
fitted.
7.Release sensor from rear hub and remove
sensor and harness.
8.Remove bush from rear hub.
Refit
1.Clean sensor and rear hub mating faces.
2.Fit new bush to rear hub.
3.Apply anti-seize grease to sensor.
4.Fit sensor to hub, ensure sensor is fully seated
in hub.
CAUTION: Ensure ABS sensor is fully
located into hub, so that sensor touches
pole wheel teeth.
5.Fit bolt securing ABS sensor to hub, if fitted.
6.Ensure 'O' ring is in place and connect sensor
multiplug to body harness.
7.Secure multiplug in body clip.
8.Secure harness grommets to brackets.
9.Secure harness to brake hose clip.
10.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
11.Remove stands and lower vehicle.
12.To ensure correct operation, the ABS system
MUST be tested using TestBook/T4.
Page 756 of 1007
PANEL REPAIRS
BODY REPAIRS 77-2-1
PANEL REPAIRS
General
Body shells are of monocoque construction. Front and rear sections of the shell are designed as 'energy absorbing'
zones. This means they are designed to deform progressively when subjected to impact in order to minimise the
likelihood of injury to vehicle occupants.
It is essential that design dimensions and strength are restored in accident rectification. It is important that neither
structural weakness nor excessive local stiffness are introduced into the vehicle during body repair.
Repairs usually involve a combination of operations ranging from straightening procedures to renewal of individual
panels or panel assemblies. The repairer will determine the repair method and this decision will take into account a
balance of economics between labour and material costs and the availability of repair facilities in both equipment and
skills. It may also involve considerations of the vehicles' downtime, replacement vehicle availability and repair turn-
around time.
It is expected that a repairer will select the best and most economic repair method possible, making use of the facilities
available. The instructions given are intended to assist a skilled body repairer by expanding approved procedures for
panel replacement. The objective is to restore the vehicle to a safe running condition by carrying out a repair which is
as close as is feasible to original standard. The results should not advertise to the experienced eye that the vehicle
has been damaged, although the repair might not be identical in all respects to the original factory build. Commercial
bodyshop repair facilities cannot always duplicate methods of construction used during production.
Operations covered in this Manual do not include reference to testing the vehicle after repair. It is essential that work
is inspected and suspension geometry checked after completion. Where necessary a road test of the vehicle should
be carried out, particularly where safety-related items are concerned.
Where major units have been disconnected or removed it is necessary to ensure that fluid levels are checked and
topped up where necessary. It is also necessary to ensure that the repaired vehicle is in a roadworthy condition in
respect of tyre pressures, lights, washer fluid etc.
Body repairs often involve the removal of mechanical and electrical units and associated wiring. Where necessary,
refer to the relevant section of the Workshop Manual for removal and refitting instructions.
Body components
Taking into consideration the differences in body styles, suspension systems and engine and transmission layouts,
the location of the following components as applicable to a particular vehicle is critical:
lFront suspension upper damper mountings.
lFront suspension or sub frame mountings.
lRear suspension upper damper mountings.
lRear suspension mountings or lower pivots.
Additional points which can be used to check alignment and assembly are:
lInner holes in crossmember - side - main floor.
lHoles in front longitudinals.
lHoles in side members.
lHoles in rear longitudinals.
lHoles in rear lower panels or extension rear floor.
Apertures for windscreen, backlight, bonnet and doors can be measured and checked using the dimensional
information provided and also by offering up an undamaged component as a gauge.
Straightening
Whenever possible, structural members should be cold straightened under tension. Do not attempt to straighten with
a single pull but rework the damaged area using a series of pulls, releasing tension between each stage and using
the opportunity to check alignment.
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 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.