light LAND ROVER FREELANDER 2001 Manual PDF
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 2001, Model line: FREELANDER, Model: LAND ROVER FREELANDER 2001Pages: 1007, PDF Size: 23.47 MB
Page 805 of 1007
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.
Page 807 of 1007
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.
Page 810 of 1007
PANEL REPAIRS
REPAIRS 77-2-55
Inner 'e' post - 3 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 soft/hard top.
9.Remove tail door aperture seal.
10.Remove rear quarter lower casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 3 door.
11.Remove loadspace carpet.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
12.Release vehicle harness from 'E' post and
position aside.
13. LH side: Remove tail door striker.
14. RH side: Remove tail door.
+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
15. RH side: Remove fuel filler neck.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Filler neck.
16. RH side: Remove fuel tank.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.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 811 of 1007
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.
Page 812 of 1007
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.
Page 826 of 1007
BODY SEALING MATERIALS
APPROVED MATERIALS 77-3-3
APPROVED MATERIALS
Description - Usage Supplier Part Number
Cavity waxes
Inner Cavity Wax (Amber) 3M 08901/11/21
Inner Cavity Wax (Transparent) 3M 08909/19/29
Cavity Wax Croda PW57
Engine bay waxes/lacquers
Astrolan Engine Bay Wax and Cosmetic Wax Astors DA3243/1
Engine Bay and Cosmetic Wax/Lacquer Croda PW197
Engine Bay Cosmetic Wax/Lacquer Dinol 4010
Miscellaneous materials
Aerosol Auto Adhesive (Trim) - impact adhesive for trim parts 3M 08080
Flexible Parts Repair Material - rubber modified polypropylene parts 3M 05900
Sound Dampening Foam Gurit-Essex Betacore 7999
Sound Dampening Pillar Foam Duramix 4330
Flexible Foam (anti-flutter) - used between panels, allows for a degree of
movementDuramix 4320
Water Shedder Repair (Aerosol) Teroson -
Seam sealers
Body Caulking - type (b) gaps between panels 3M 08568
Drip Chek Clear - bolted, spot welded and bonded panel edges; type(a) and (b)
gaps between panels; type (c) clinch joints3M 08401
Drip Chek Heavy - type (b) gaps between panels; type (c) clinch joints 3M 08531
Description - Usage Supplier Part Number
Seam sealers (continued)
Polyurethane Seam Sealer - bolted, spot welded and bonded panel edges; type
(a) and (b) gaps between panels; type (b) clinch joints3M 08684/89/94
Polyurethane Sealer (Sachet) - bolted panel edges; type (b) clinch joints 3M 08703/83/88
Sprayable Sealer - lap joints 3M 08800/23
Super Seam Sealer - lap joints; type (b) clinch joints 3M 08537
Weld Thru' Sealer - between spot welded panels 3M 08626
Betafill Clinch and Brushable Sealer - type (b) clinch joints Gurit-Essex 10211/15/20
Clinch, Joint and Underbody Coating - lap joints Gurit-Essex 10101/10707
Leak Chek Clear - between bolted panels; spot welded and bonded panel edges;
type (c) clinch joints; type (a) gaps between panelsKent Industries 10075
Putty - type (b) gaps between panels Kent Industries -
Polyurethane Seam Sealer - bolted, spot welded and bonded panel edges;
between bonded panels; type (a) and (b) gaps between panelsPPG 6500
Polyurethane Seam Sealer - bolted, spot welded and bonded panel edges;
between bonded panels; type (b) gaps between panelsTeroson 92
Terolan Light Seam Sealer - bolted, spot welded and bonded panel edges; type
(a) and (b) gaps between panels; between bonded panels; type (c) clinch jointsTeroson -
Terolan Special Brushable Seam Sealer - lap joints Teroson -
Terostat Sprayable Seam Sealer - bolted, spot welded and bonded panel edges;
between bonded panels; type (b) gaps between panelsTeroson 9320
Terostat 1K PU Seam Sealer (SE 20) - type (a) and (b) gaps between panels;
spot welded and bonded panel edgesTeroson -
Sealing Compound - bolted, spot welded and bonded panel edges; between
bonded panels; type (b) gaps between panelsWurths 8901001/-/6
Page 828 of 1007
BODY SEALING MATERIALS
APPLICATION EQUIPMENT 77-3-5
APPLICATION EQUIPMENT
Application Equipment
Suitable application equipment is available from the following manufacturers and suppliers:
3M
Automotive Trades Group
3M UK Plc
3M House
PO Box 1
Market Place
Bracknell
Berks.
RG12 1JU
( (01344) 858611
Cooper Pegler
Burgess Hill
Sussex
RH15 9LA
( (014 446) 42526
SATA Spray Equipment
Minden Industrial Ltd.
16 Greyfriars Road
Moreton Hall
Bury St. Edmunds
Suffolk
IP32 7DX
( (01284) 760791
3M Body Schutz Pistol Spraygun 08996
A pistol type spraygun constructed from case and machined light alloy and designed for use with 3M screw fit Body
Schutz containers.
3M Pneumatic Cartridge Gun 08012
Air line-fed gun for applying 3M cartridge products. Excellent for ease of application to obtain a smooth bead.
Regulator valve for additional control.
3M Pneumatic Applicator Guns 08006/7
Air line-fed gun for application of 3M sachet sealers (Part Number 08006 for 200ml and 310ml sachet applications,
and Part Number 08007 for all size sachets including 600ml).
Also available: Heavy Duty Manual Gun 08013.
3M Applicator Gun 08190.
For the application of 3M Structural Adhesive 08120.
3M Inner Cavity Wax Applicator Gun 08997
This equipment accepts 1-litre canisters and has a 750mm flexible tube.
The approved system is available from all 3M refinishing factors.
Page 932 of 1007
LIGHTING
ADJUSTMENTS 86-2-1
LIGHTING ADJUST ME NTS
Headlamps - pair - align beam - up to
04MY
$% 86.40.17
Check
1.Align beam setting equipment to headlamp.
2.Switch on headlamps. Headlamp setting
lNon NAS models: 1.2% below horizontal
and parallel.
lNAS models: 0.4% below horizontal and
parallel.
Adjust
1.Adjust headlamp using a 6 mm Allen key.
2.Turn Allen screw for vertical alignment.
3. Non NAS models: Turn Allen screw for
horizontal alignment.
4.Align beam setting equipment to 2nd
headlamp.
5.Adjust 2nd headlamp as detailed above.
6.Switch off headlamps and remove beam setting
equipment.
Headlamps - pair - align beam - from
04MY
$% 86.40.17
Check
1.Align beam setting equipment to headlamp.
2.Switch on headlamps. Headlamp setting:
lNon NAS models: 1.2% below horizontal
and parallel.
lNAS models: 0.4% below horizontal and
parallel.
Adjust
1.Rotate inboard adjuster for vertical alignment.
2. Non NAS models: Rotate outboard adjuster
for horizontal alignment.
NOTE: The outboard adjuster is accessible via
a slot in rear face of headlamp.
3.Align beam setting equipment to 2nd
headlamp.
4.Adjust 2nd headlamp as detailed above.
5.Switch off headlamps and remove beam setting
equipment.
Page 934 of 1007
LIGHTING
REPAIRS 86-2-3
REPAIRS
Headlamp assembly - up to 04MY
$% 86.40.49
Remove
1.Remove front bumper.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
2.Remove bolt and screw securing headlamp to
body.
3.Loosen nut securing headlamp to body.
4.Disconnect 2 multiplugs from headlamp and
remove headlamp.Refit
1.Position headlamp and connect multiplugs.
2.Fit and tighten bolt, screw and nut securing
headlamp.
3.Fit front bumper.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
4.Check headlamp adjustment.
+ LIGHTING, ADJUSTMENTS,
Headlamps - pair - align beam - up to 04MY.
Page 935 of 1007
LIGHTING
86-2-4 REPAIRS
Headlamp assembly - from 04MY
$% 86.40.49
Remove
1.Remove front bumper.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - from 04MY.
2.Remove 2 bolts securing headlamp support
bracket and remove bracket.
3.Remove 2 bolts and a nut securing headlamp
and release headlamp.
4.Disconnect multiplug from headlamp.
5.Release clip securing headlamp harness to
headlamp and remove headlamp.Refit
1.Position headlamp, connect multiplug to
headlamp and secure headlamp harness clip.
2.Fit headlamp to aperture and tighten nut and 2
bolts to 3 Nm (2.2 lbf.ft).
3.Fit headlamp support bracket and tighten bolts
to 3 Nm (2.2 lbf.ft).
4.Fit front bumper.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - from 04MY.
5.Check headlamp alignment and adjust if
necessary.
+ LIGHTING, ADJUSTMENTS,
Headlamps - pair - align beam - from 04MY.
M86 6113