roof LAND ROVER FREELANDER 2001 Workshop Manual

CONTENTS
CONTENTS 13
Remote control - front door ............................................................................................................. 76-1-30
Remote control - rear door .............................................................................................................. 76-1-30
Operating cable - lock remote control - 5 door ............................................................................... 76-1-31
Finisher - rear screen - side - 5 door .............................................................................................. 76-1-31
Handle - exterior - rear door ........................................................................................................... 76-1-32
Handle - exterior - tail door ............................................................................................................. 76-1-33
Handle - exterior - front door ........................................................................................................... 76-1-34
Door pull - 5 door - up to 04MY ....................................................................................................... 76-1-35
EXTERIOR FITTINGS ............................................................................... 76-2-1
REPAIRS
Wing - front ..................................................................................................................................... 76-2-1
Liner - front wheel arch ................................................................................................................... 76-2-2
Liner - rear wheel arch .................................................................................................................... 76-2-3
Panel - underbelly ........................................................................................................................... 76-2-4
Mirror - exterior - electric ................................................................................................................. 76-2-4
Mud flap - front ................................................................................................................................ 76-2-5
Mud flap - rear ................................................................................................................................. 76-2-5
Bracket - spare wheel mounting ..................................................................................................... 76-2-6
Side rail - integral roof rack - 5 door ................................................................................................ 76-2-7
Bonnet............................................................................................................................................. 76-2-7
Cable/rod - bonnet lock control ....................................................................................................... 76-2-8
Bumper - assembly - front - up to 04MY ......................................................................................... 76-2-10
Bumper - assembly - front - from 04MY .......................................................................................... 76-2-11
Bumper valance - rear - up to 04MY ............................................................................................... 76-2-13
Bumper valance - rear - from 04MY ................................................................................................ 76-2-13
Finisher - sill - lower ....................................................................................................................... 76-2-16
Moulding - roof - 5 door ................................................................................................................... 76-2-17
Wheelarch extension - rear wing part ............................................................................................. 76-2-18
Body quarter vent assembly - 3 door .............................................................................................. 76-2-19

CONTENTS
CONTENTS 15
SUNROOF................................................................................................. 76-6-1
REPAIRS
Sun/sliding roof - complete - front - 3 door ..................................................................................... 76-6-1
Wind deflector - sun/sliding roof - 3 door ....................................................................................... 76-6-2
Seal - tray - sun /sliding roof - front ................................................................................................ 76-6-3
Sun/sliding roof - complete - front - 5 door ..................................................................................... 76-6-4
Glass panel - sun/sliding roof - front - 5 door ................................................................................. 76-6-4
Seal - panel glass - sun roof - 5 door .............................................................................................. 76-6-5
Motor - sun/sliding roof - front - 5 door ........................................................................................... 76-6-5
Drive cables & slide assemblies - sun/sliding roof - front - 5 door ................................................. 76-6-7
Drain tube - sun/sliding roof - front - each - 5 door ........................................................................ 76-6-8
Drain tube - sun/sliding roof - rear - each - 5 door ......................................................................... 76-6-9
Finisher - flange to headlining - front ............................................................................................. 76-6-9
Wind deflector - sun/sliding roof - 5 door ........................................................................................ 76-6-10
Sun blind - front - one - 5 door ....................................................................................................... 76-6-10
Switch - sun/sliding roof - front ....................................................................................................... 76-6-11
Seal - tray - sun /sliding roof - front - 5 door ................................................................................... 76-6-11
HOOD ........................................................................................................ 76-7-1
REPAIRS
Hard top - remove for access & refit ............................................................................................... 76-7-1
Frame & hood cover - assembly - remove for access & refit ......................................................... 76-7-2
Hood outer cover ............................................................................................................................ 76-7-4
Glass - body side - hard back ......................................................................................................... 76-7-5
Seal - hard back - primary............................................................................................................... 76-7-7
Catch and retainer - hard-back - front ............................................................................................. 76-7-8
Catch and retainer - hard-back - rear .............................................................................................. 76-7-9
BODY DIMENSIONS ................................................................................ 77-1-1
BODY DIMENSIONS
Dimensional Information ................................................................................................................. 77-1-1
Dimensional Illustrations ................................................................................................................. 77-1-3
BODY GAPS AND PROFILES
Gap and Profile Measurements ...................................................................................................... 77-1-17

CONTENTS
16 CONTENTS
PANEL REPAIRS...................................................................................... 77-2-1
BODY REPAIRS
General ........................................................................................................................................... 77-2-1
REPLACEMENT PANELS
Serviceable Panels ......................................................................................................................... 77-2-3
Inner front end panels ..................................................................................................................... 77-2-4
Outer body side panels - 3 door ..................................................................................................... 77-2-5
Outer body side panels - 5 door ..................................................................................................... 77-2-6
Front inner body side panels - 3 door ............................................................................................. 77-2-7
Front inner body side panels - 5 door ............................................................................................. 77-2-8
Rear inner body side panels - 3 door.............................................................................................. 77-2-9
Rear inner body side panels - 5 door.............................................................................................. 77-2-10
Roof assemblies - 3 door ................................................................................................................ 77-2-11
Roof assembly - 5 door................................................................................................................... 77-2-12
Rear end panels ............................................................................................................................. 77-2-13
Door assemblies ............................................................................................................................. 77-2-14
WELDING PROCEDURES
ECU locations (3 door model shown, 5 door model similar) ........................................................... 77-2-15
General Welding Precautions ......................................................................................................... 77-2-16
PROCEDURES
Panel replacement procedure......................................................................................................... 77-2-19
REPAIRS
Front bulkhead assembly ............................................................................................................... 77-2-25
Bonnet locking platform .................................................................................................................. 77-2-27
Headlamp mounting panel .............................................................................................................. 77-2-28
Front lower crossmember .............................................................................................................. 77-2-29
Front sidemember (complete) ........................................................................................................ 77-2-30
Front sidemember (front section) ................................................................................................... 77-2-32
Front valance assembly ................................................................................................................. 77-2-33
Valance upper front ....................................................................................................................... 77-2-36
Valance front .................................................................................................................................. 77-2-37
Valance outer reinforcement .......................................................................................................... 77-2-39
'A' post - 3 door .............................................................................................................................. 77-2-40
'A' post - 5 door .............................................................................................................................. 77-2-41
Sill reinforcement - 3 door .............................................................................................................. 77-2-43
Sill reinforcement - 5 door .............................................................................................................. 77-2-44
'B/C' post reinforcement - 3 door ................................................................................................... 77-2-45
'B/C' post reinforcement - 5 door ................................................................................................... 77-2-46
Complete rear quarter - 3 door ...................................................................................................... 77-2-48
Complete rear quarter - 5 door ...................................................................................................... 77-2-50
Outer rear wheel arch - 3 door ....................................................................................................... 77-2-53
Outer rear wheel arch - 5 door ....................................................................................................... 77-2-54
Inner 'e' post - 3 door ..................................................................................................................... 77-2-55
Inner 'e' post - 5 door ..................................................................................................................... 77-2-56
Rear floor crossmember assembly ................................................................................................ 77-2-58
Rear floor ........................................................................................................................................ 77-2-59
Floor longitudinal ............................................................................................................................ 77-2-60
Front roof assembly - 3 door .......................................................................................................... 77-2-61
Rear roof assembly - 3 door .......................................................................................................... 77-2-61
Roof assembly - 5 door .................................................................................................................. 77-2-62
TIMES
TIME SCHEDULES ........................................................................................................................ 77-2-63

CONTENTS
20 CONTENTS
LIGHTING.................................................................................................. 86-2-1
ADJUSTMENTS
Headlamps - pair - align beam - up to 04MY .................................................................................. 86-2-1
Headlamps - pair - align beam - from 04MY ................................................................................... 86-2-1
REPAIRS
Headlamp assembly - up to 04MY.................................................................................................. 86-2-3
Headlamp assembly - from 04MY .................................................................................................. 86-2-4
Lamp assembly - flasher side repeater - front ................................................................................ 86-2-5
Lamp assembly - tail ....................................................................................................................... 86-2-5
Lamp assembly - number plate ...................................................................................................... 86-2-6
Lamp assembly - fog/driving - from 04MY ...................................................................................... 86-2-6
Lamp assembly - rear ..................................................................................................................... 86-2-7
Lamp assembly - centre high mounted stop (CHMSL) ................................................................... 86-2-7
Lamp assembly - glove compartment ............................................................................................. 86-2-8
Lamp assembly - load space .......................................................................................................... 86-2-8
Switch - headlamp levelling ............................................................................................................ 86-2-9
Switch - glove compartment ........................................................................................................... 86-2-9
Switch - hazard warning ................................................................................................................. 86-2-10
Switch - combined direction indicator/headlight/horn ..................................................................... 86-2-10
Switch - rear fog lamp ..................................................................................................................... 86-2-11
CONTROL UNITS ..................................................................................... 86-3-1
REPAIRS
Control unit - window lift ................................................................................................................. 86-3-1
Relay - power folding mirrors - from 02MY ..................................................................................... 86-3-1
Central Control Unit (CCU) ............................................................................................................. 86-3-2
Control Unit - power fold mirrors - up to 02MY ............................................................................... 86-3-3
SECURITY................................................................................................. 86-4-1
REPAIRS
Solenoid/motor - taildoor................................................................................................................. 86-4-1
Switch/push - horn .......................................................................................................................... 86-4-2
Horn ................................................................................................................................................ 86-4-2
Immobilisation - electronic control unit (ECU) - ............................................................................. 86-4-3
Sensor - volumetric - alarm system - 3 door ................................................................................... 86-4-3
Module (ECU) - volumetric - alarm system - 5 door - without sunroof ........................................... 86-4-5
Module (ECU) - volumetric - alarm system - 5 door - with sunroof ................................................ 86-4-7
Receiver - alarm system ................................................................................................................. 86-4-10
Coil - passive immobilisation - alarm system .................................................................................. 86-4-10

GENERAL INFORMATION
03-18
Fuel handling precautions
Fuel vapour is highly inflammable and in confined
spaces is also explosive and toxic. The vapour is
heavier than air and will always fall to the lowest
level. The vapour can easily be distributed
throughout a workshop by air currents;
consequently, even a small spillage of fuel is
potentially very dangerous.
The following information provides basic precautions
which must be observed if petrol (gasoline) is to be
handled safely. It also outlines other areas of risk
which must not be ignored. This information is issued
for basic guidance only, if in doubt consult your local
Fire Officer.
General
Always have a fire extinguisher containing FOAM,
CO
2, GAS or POWDER close at hand when handling
or draining fuel or when dismantling fuel systems.
Fire extinguishers should also be located in areas
where fuel containers are stored.
Always disconnect the vehicle battery before
carrying out dismantling or draining work on a fuel
system.
Whenever fuel is being handled, drained or stored, or
when fuel systems are being dismantled, all forms of
ignition must be extinguished or removed; any
leadlamps must be flameproof and kept clear of
spillage.
WARNING: No one should be permitted to repair
components associated with fuel without first
having specialist training.
WARNING: Do not remove fuel system
components while the vehicle is over a pit.Fuel tank draining
Fuel tank draining should be carried out in
accordance with the procedure outlined in the FUEL
DELIVERY section of this manual and observing the
following precautions:
WARNING: Fuel must not be extracted or drained
from any vehicle while it is over a pit. Extraction
or draining of fuel must be carried out in a well
ventilated area.
The capacity of containers must be more than
adequate for the amount of fuel to be extracted or
drained. The container should be clearly marked
with its contents and placed in a safe storage
area which meets the requirements of local
authority regulations.
WARNING: When fuel has been drained from a
fuel tank the precautions governing naked lights
and ignition sources should be maintained.
Fuel tank removal
When the fuel line is secured to the fuel tank outlet by
a spring steel clip, the clip must be released before
the fuel line is disconnected or the fuel tank is
removed. This procedure will avoid the possibility of
residual petrol fumes in the fuel tank being ignited
when the clip is released.
As an added precaution, fuel tanks should have a
'FUEL VAPOUR' warning label attached to them as
soon as they are removed from the vehicle.
Fuel tank repairs
No attempt should be made to repair a plastic fuel
tank. If the structure of the tank is damaged, a new
tank must be fitted.
Body repairs
Plastic fuel pipes are particularly susceptible to heat,
even at relatively low temperature, and can be
melted by heat conducted from some distance away.
When body repairs involve the use of heat, all fuel
pipes which run in the vicinity of the repair area must
be removed, and the tank outlet plugged.

GENERAL INFORMATION
03-29
Air conditioning system precautions
General
The air conditioning system contains fluids and
components which could be potentially hazardous to
the service engineer or the environment if not
serviced and handled correctly. The following
guidelines are intended to alert the service engineer
to potential sources of danger and emphasise the
importance of ensuring the integrity of the Air
Conditioning operating conditions and components
fitted to the vehicle.
Where necessary, additional specific precautions are
detailed in the relevant sections of this Manual which
should be referred to prior to commencing repair
operations.
The refrigerant used in the air conditioning system is
HFC-134a (Hydrofluorocarbon) R134a. Always
adhere to the following precautions:
WARNING: Servicing must only be carried out by
personnel familiar with both the vehicle system
and the charging and testing equipment. All
operations must be carried out in a well
ventilated area away from open flame and heat
sources.
WARNING: Do not allow a refrigerant container to
be heated by direct flame or to be placed near
any heating appliance. A refrigerant container
must not be heated above 50
°C.
Do not leave a container of refrigerant without its
cap fitted. Do not transport a container of
refrigerant that is unrestrained, especially in the
boot of a car.
WARNING: Do not smoke or weld in areas where
R134a is in use. Inhalation of concentrations of
vapour can cause dizziness, disorientation,
incoordination, narcosis, nausea or vomiting.
R134a is odourless and colourless. Do not
handle or discharge in an enclosed area, or any
area where the vapour and liquid can come in
contact with a naked flame or hot metal. R134a is
not flammable but can cause a highly toxic gas.
WARNING: Do not allow fluids other than R134a
or compressor lubricant to enter the air
conditioning system. Spontaneous combustion
may occur.WARNING: R134a is a hazardous liquid and when
handled incorrectly can cause serious injury.
Suitable protective clothing, consisting of face
protection, heat proof gloves, rubber boots and
rubber apron or waterproof overalls, must be
worn when carrying out operations on the air
conditioning system.
WARNING: Due to its low evaporating
temperature, R134a must be handled with care.
R134a splashed on any part of the body will
cause immediate freezing of that area. Also,
refrigerant cylinders and replenishment trolleys
when discharging will freeze skin to them if
contact is made.
WARNING: Under no circumstances should
refrigerant hoses be disconnected without first
discharging the system.
Do not disconnect any pipes in an air
conditioning refrigeration system unless trained
and instructed to do so. A refrigerant is used
which can cause blindness if allowed to contact
eyes.
WARNING: Refrigerant must always be recycled
before re-use to ensure that the purity of the
refrigerant is high enough for safe use in the air
conditioning system.
Recycling should always be carried out with
equipment which is design certified by
Underwriter Laboratory Inc. for compliance with
SAE J1991. Other equipment may not recycle
refrigerant to the required level of purity.
A R134a Refrigerant Recovery Recycling
Recharging Station must not be used with any
other type of refrigerant.
Refrigerant R134a from domestic and
commercial sources must not be used in motor
vehicle air conditioning systems.

GENERAL DATA
04-35
Dimensions
* At EEC kerb weight
Overall length (inc. 195/80 spare wheel/tyre):
⇒ K1.8 4368 mm (14 ft 4 in)
⇒ KV6 4433 mm (14 ft 7 in)
⇒ Td4 4368 mm (14 ft 4 in)
Overall width (including mirrors 2.068 m (6 ft 9.4 in)
Overall height (including roof bars and cross rails)* 1.708 m (5 ft 7.2 in)
Overall height (including roof bars and cross rails)*
⇒ 3 door 1.808 m (5 ft 11.2 in)
⇒ 5 door 1.828 m (5 ft 11.9 in)
Ground clearance (minimum)*: 186 mm (7.3 in)
Wading depth (maximum) 400 mm (15.7 in)
Wheelbase 2.557 m (8 ft 4.7 in)
Maximum approach angle
*30.5°
Maximum departure angle (with towbar)
*24°
Maximum departure angle (without towbar)
*33.9°
Maximum breakover angle 24°
Track:
⇒ Front
⇒ Rear1534 mm (60.4 in)
1545 mm (60.8 in)

GENERAL DATA
04-36
Weights
†To increase stability, it is recommended that the nose weight is adjusted to the maximum limit, when loading to the
maximum trailer weight.
*If the vehicle trailer weight exceeds 1800 kg the vehicle payload must be restricted to less than the Gross Vehicle
Weight to ensure the loaded combination is within the Gross Train Weight limit.
**The Gross Towing Weight must be reduced by 300 kg (662 lb) when the following conditions exist:
climbing steep hills and mountains with air temperatures above 30
°C/ 86°F.
altitudes of 1000 metres (3280 feet) and above.
Unladen weight (full fuel tank, excluding options):
⇒ Petrol models 1410 - 1620 kg (3109 -3572 lb)
⇒ Diesel models 1540 - 1635 kg (3395 - 3605 lb)
Maximum gross vehicle weight:
⇒ Td4 engine 2080 kg (4586 lb)
⇒ K1.8 engine 2040 kg (4497 lb)
⇒ KV6 engine 2060 kg (4542 lb)
Maximum front axle load:
⇒ Td4 engine 1100 kg (2425 lb)
⇒ K1.8 engine 1050 kg (2315 lb)
⇒ KV6 engine 1080 kg (2381 lb)
Maximum rear axle load (must NOT be exceeded) 1120 kg (2470 lb)
Maximum trailer weight
*2000 kg (4410 lb)
Maximum Gross Towing Weight (GTW)
**:
⇒ Td4 engine 3880 kg (8554 lb)
⇒ K1.8 engine 3840 kg (8466 lb)
⇒ KV6 engine 3860 kg (8510 lb)
Towing hitch downward load (maximum nose weight)
†140 kg (309 lb)
Maximum roof rack load (includes weight of rack) 75 kg (165 lb)

TORQUE WRENCH SETTINGS
06-30
Body
TORQUE DESCRIPTION METRIC IMPERIAL
Doors
Door lock striker to body screws 10 Nm 7 lbf.ft
Door stiffener Torx screws 9 Nm 7 lbf.ft
Front door control unit to glass clamp bolts 9 Nm 7 lbf.ft
Front door hinge bolts 30 Nm 22 lbf.ft
Rear door glass clamp bolts 8 Nm 6 lbf.ft
Tail door exterior handle nuts 5 Nm 3.7 lbf.ft
Tail door glass clamp bolts 8 Nm 6 lbf.ft
Tail door glass regulator lock nuts 14 Nm 10 lbf.ft
Tail door hinge bolts 30 Nm 22 lbf.ft
Exterior Fittings
Bonnet hinge, bolts 9 Nm 6.5 lbf.ft
Bonnet release lever to 'A' post bolt 9 Nm 6.5 lbf.ft
Exterior mirror to door Torx screws 6 Nm 4.4 lbf.ft
Front wing bolts5 Nm 3.7 lbf.ft
Spare wheel mounting bracket:
⇒ Bolts13 Nm 10 lbf.ft
⇒ Nuts25 Nm 18 lbf.ft
Spare wheel to bracket retention nuts 45 Nm 33 lbf.ft
Splash shield bolts 10 Nm 7 lbf.ft
Underbelly panel to body bolts 45 Nm 33 lbf.ft
Underbelly panel to body rear screws 8 Nm 6 lbf.ft
3 door vehicles
Hard back catch Torx screws 10 Nm 7.5 lbf.ft
Hard back retainer Torx screws 10 Nm 7.5 lbf.ft
Soft back support bracket bolts 25 Nm 18 lbf.ft
5 door vehicles
Roof rack side rail bolts 22 Nm 16 lbf.ft
Interior Trim Components
Engine compartment fusebox bolts 8 Nm 6 lbf.ft
Passenger compartment fusebox mounting plate to body and steering column
bracket bolts8 Nm 6 lbf.ft
Passenger compartment fusebox to mounting plate bolts 8 Nm 6 lbf.ft
Seats
Front seat runner to body bolts 45 Nm 33 lbf.ft
Front seat squab frame to cushion frame Torx bolts 45 Nm 33 lbf.ft
Rear bench seat to body bolts 25 Nm 18 lbf.ft
Rear seat cushion to squab Torx bolts 28 Nm 21 lbf.ft
Rear seat catch assembly Torx bolts 32 Nm 24 lbf.ft
Rear seat squab lock Torx screws 20 Nm 15 lbf.ft
Rear seat squab to cushion Torx bolts 28 Nm 21 lbf.ft
Rear seat hinge Torx bolts 25 Nm 18 lbf.ft

TORQUE WRENCH SETTINGS
06-31
Seat belts (3-door models)
Front seat belt loop to 'B' post bolt 31 Nm 23 lbf.ft
Front seat belt pre-tensioner and buckle to seat frame Torx bolt 32 Nm 24 lbf.ft
Front seat belt reel bolt 31 Nm 23 lbf.ft
Front seat belt slider bar bolts 40 Nm 30 lbf.ft
Front seat belt lower mounting Torx bolts 40 Nm 30 lbf.ft
Front seat belt upper mounting Torx bolt 31 Nm 23 lbf.ft
Rear seat belt and buckle to frame Torx bolts 32 Nm 24 lbf.ft
Rear seat belt lower fixing to body bolt 50 Nm 37 lbf.ft
Rear seat belt reel to squab nut 32 Nm 24 lbf.ft
Rear seat belt upper mounting bolt 32 Nm 24 lbf.ft
Rear seat squab lock Torx screws 20 Nm 15 lbf.ft
Seat belt pre-tensioner to seat bolt 32 Nm 24 lbf.ft
Seat belts (5-door models)
Front seat belt adjuster to 'B' post Torx bolts 26 Nm 19 lbf.ft
Front seat belt upper anchorage to adjuster mounting nut 31 Nm 23 lbf.ft
Front seat belt lower fixing to 'B' post bolt 40 Nm 30 lbf.ft
Front seat belt pre-tensioner and buckle to seat frame Torx bolt 32 Nm 24 lbf.ft
Front seat belt reel bolt 31 Nm 23 lbf.ft
Rear centre seat belt reel to seat squab nut 32 Nm 24 lbf.ft
Rear seat belt and buckle bolts 32 Nm 24 lbf.ft
Rear side seat belt lower fixing bolt 40 Nm 30 lbf.ft
Rear side seat belt reel bolt 50 Nm 37 lbf.ft
Rear side seat belt buckle to catch assembly bolt 32 Nm 24 lbf.ft
Rear side seat belt upper mounting bolt 32 Nm 24 lbf.ft
Seat belt height adjuster bolts 26 Nm 19 lbf.ft
Screens
Sun roof side rail Torx bolts 22 Nm 16 lbf.ft TORQUE DESCRIPTION METRIC IMPERIAL