2001 LAND ROVER FREELANDER suspension

PANEL REPAIRS
REPAIRS 77-2-51
23.Remove rear body side glass.

+ SCREENS, REPAIRS, Glass - body
side - rear.
24.Remove rear damper.

+ REAR SUSPENSION, REPAIRS,
Damper.
25.Release vehicle harness from rear quarter and
position aside.
26. LH side: Remove tail door striker from 'E' post.
27. RH side: Remove tail door.

+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
28. RH side: Remove fuel filler neck.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Filler neck.
29. RH side: Remove fuel tank.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.Repair

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
REPAIRS 77-2-53
Outer rear wheel arch - 3 door
In this procedure, the squab side reinforcement is
replaced in conjunction with the outer rear wheel
arch.
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 rear quarter lower casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 3 door.
8.Remove rear seat.

+ SEATS, REPAIRS, Rear seat - LH.

+ SEATS, REPAIRS, Rear seat - RH.
9.Remove rear body side casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - body side - rear - 3
door.
10.Remove rear damper.

+ REAR SUSPENSION, REPAIRS,
Damper.
11. RH side: Remove fuel filler neck.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Filler neck.
12. 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.
Refit
1. RH side: Fit fuel tank.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.
2. RH side: Fit fuel filler neck.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Filler neck.
3.Fit rear damper.

+ REAR SUSPENSION, REPAIRS,
Damper.
4.Fit rear body side casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - body side - rear - 3
door.
5.Fit rear seat.

+ SEATS, REPAIRS, Rear seat - LH.

+ SEATS, REPAIRS, Rear seat - RH.
6.Fit rear quarter lower casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 3 door.
7.Fit rear wheel arch liner.
8.Fit rear bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
9.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
10.Connect all ECUs.
11.Connect alternator.
12.Connect battery earth lead.

PANEL REPAIRS
77-2-54 REPAIRS
Outer rear wheel arch - 5 door
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 rear quarter lower casing.

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

+ SEATS, REPAIRS, Rear seat - LH.

+ SEATS, REPAIRS, Rear seat - RH.
9.Remove rear damper.

+ REAR SUSPENSION, REPAIRS,
Damper.
10. RH side: Remove fuel filler neck.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Filler neck.
11. 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. Refit
1. RH side: Fit fuel tank.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.
2. RH side: Fit fuel filler neck.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Filler neck.
3.Fit rear damper.

+ REAR SUSPENSION, REPAIRS,
Damper.
4.Fit rear seat.

+ SEATS, REPAIRS, Rear seat - LH.

+ SEATS, REPAIRS, Rear seat - RH.
5.Fit rear quarter lower casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
6.Fit rear wheel arch liner.
7.Fit rear bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
8.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
9.Connect all ECUs.
10.Connect alternator.
11.Connect battery earth lead.

CORROSION PREVENTION AND SEALING
77-4-8 SEALING
Underbody sealer
Underfloor areas and sill outer panels are treated with a Plastisol PVC underbody sealer. This material is not suitable
for re-treatment. When repairing areas of underbody sealer, strip the factory-applied underbody sealer back to a
suitable break point. Ensure that a clean metal surface is exposed and that the edge of the existing sealer adheres
soundly to the panel.
Apply new underbody sealer between primer and surfacer paint operations. Apply seam sealer as necessary before
application of underbody sealer. Ensure that blanking plugs and grommets in the floor pan (except those used for wax
injection) are fitted before underbody sealer application. Refit any heat-fusible plugs which have been disturbed in
repair with the aid of a hot air blower, or replace with rubber grommets.
caut : Ensure that suspension units, wheels, tyres, power unit, driveshafts, exhaust and brakes (including all mounting
points) are shielded prior to application of fresh underbody sealer.
Underbody wax
The underbody wax must be reinstated following all repairs affecting floor panels. The wax is applied over paints and
underbody sealers.
caut : Remove old underbody wax completely from a zone extending at least 200mm beyond the area where new
underbody sealer is to be applied.
Engine bay wax
Reinstate all protective engine bay wax disturbed during repairs using an approved material.
Where repairs have involved replacement of engine bay panels, treat the entire engine compartment including all
components, clips and other fixtures with an approved underbonnet lacquer or wax.
Precautions during body repairs and handling
Take care when handling the vehicle in the workshop. Underbody sealers, seam sealers, underbody wax and body
panels may be damaged if the vehicle is carelessly lifted.
Proprietary anti-corrosion treatments
The application of proprietary anti-corrosion treatments in addition to the factory-applied treatment could invalidate
the Corrosion Warranty and should be discouraged. This does not apply to approved, compatible, preservative waxes
which may be applied on top of existing coatings.
Fitting approved accessories
When fitting accessories ensure that the vehicle's corrosion protection is not affected, either by breaking the protective
coating or by introducing a moisture trap.
Do not screw self-tapping screws directly into body panels. Fit suitable plastic inserts to the panel beforehand. Always
ensure that the edges of holes drilled into panels, chassis members and other body parts are protected with a suitable
zinc rich or acid etch primer, and follow with a protective wax coating brushed onto the surrounding area.
Do not attach painted metal surfaces of any accessory directly to the vehicle's bodywork unless suitably protected.
Where metal faces are bolted together always interpose a suitable interface material such as weldable zinc rich
primer, extruded strip, or zinc tape.
Steam cleaning and dewaxing
Due to the high temperatures generated by steam cleaning equipment, there is a risk that certain trim components
could be damaged and some adhesives and corrosion prevention materials softened or liquified.
Adjust the equipment so that the nozzle temperature does not exceed 90°C (194°F). Take care not to allow the steam
jet to dwell on one area, and keep the nozzle at least 300mm from panel surfaces.
DO NOT remove wax or lacquer from underbody or underbonnet areas during repairs. Should it be necessary to
steam clean these areas, apply a new coating of wax or underbody protection as soon as possible.

CORROSION PREVENTION AND SEALING
SEALING 77-4-9
Inspections during maintenance servicing
It is a requirement of the Corrosion Warranty that the vehicle body is checked for corrosion by an authorised Land
Rover Dealer at least once a year, to ensure that the factory-applied protection remains effective.
Service Job Sheets include the following operations to check bodywork for corrosion:
lWith the vehicle on a lift, carry out visual check of underbody sealer for damage.
lWith the vehicle lowered, inspect exterior paintwork for damage and body panels for corrosion.
The vehicle must be washed and free from deposits prior to inspection. It is part of the owner's responsibility to ensure
that the vehicle is kept free of accumulations of mud which could accelerate the onset of corrosion. It will be necessary
for the vehicle to be washed by the Dealer prior to inspection of bodywork if the customer has offered the vehicle in
a dirty condition. Particular attention should be paid to areas where access is difficult.
The checks described above are intended to be visual only. It is not intended that the operator should remove trim
panels, finishers, rubbing strips or sound-deadening materials when checking the vehicle for corrosion and paint
damage.
With the vehicle on a lift, and using an inspection or spot lamp, visually check for the following:
lCorrosion damage and damaged paintwork, condition of underbody sealer on front and rear lower panels, sills
and wheel arches.
lDamage to underbody sealer. Corrosion in areas adjacent to suspension mountings and fuel tank fixings.
The presence of small blisters in underbody sealer is acceptable, providing they do not expose bare metal.
Pay special attention to signs of damage caused to panels or corrosion protection material by incorrect jack
positioning.
caut : It is essential to follow the correct jacking and lifting procedures.
With the vehicle lowered, visually check for evidence of damage and corrosion on all visible painted areas, in
particular the following:
lFront edge of bonnet.
lVisible flanges in engine compartment.
lLower body and door panels.
Rectify any bodywork damage or evidence of corrosion found during inspection as soon as is practicable, both to
minimise the extent of the damage and to ensure the long term effectiveness of the factory-applied corrosion
prevention treatment. Where the cost of rectification work is the owner's responsibility, the Dealer must advise the
owner and endorse the relevant documentation accordingly.
Where corrosion has become evident and is emanating from beneath a removable component (e.g. trim panel,
window glass, seat etc.), remove the component as required to permit effective rectification.

CORROSION PREVENTION AND SEALING
77-4-24 SEALING
Sealed seams in front wheelarch, engine compartment and screen rail
Seams symmetrically opposite to those shown are also treated. Use putty on seams marked 'A'. On windscreen rail,
sealant to be finished flush to adjacent surfaces over length 'B'. On front suspension turrets, ensure damper mounting
holes are kept free of sealant.

HEATING AND VENTILATION
REPAIRS 80-13
21.Disconnect 3 Lucar connections from PTC
element.
22.Release cable ties securing PTC harness to
main harness.
23.Remove air intake plenum.

+ HEATING AND VENTILATION,
REPAIRS, Plenum - air intake.
24.Release 2 clips securing PTC harness from
plenum box section.
25.With assistance release 2 grommets from
bulkhead and remove PTC harness from
vehicle.Refit
1.With assistance route PTC harness through
bulkhead and fit grommets.
2.Fit clips securing PTC harness to plenum box
3.Fit air intake plenum.

+ HEATING AND VENTILATION,
REPAIRS, Plenum - air intake.
4.Fit cable ties securing PTC harness to main
bulkhead harness.
5.Connect Lucar connections to PTC element.
6.Fit air duct.
7.Fit RH demister vent duct.
8.Fit fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
9.Connect and secure PTC harness multiplug to
engine harness.
10.Secure PTC harness/relay to bulkhead bracket
11.Fit clip to secure PTC harness to ECM housing
bracket.
12.Fit PTC positive leads to (80 amp) fuse holder,
fit and tighten nuts to 7 Nm (5.2 lbf.ft).
13.Fit (80 amp) fuse cover.
14.Secure PTC harness/relays to ECM housing
bracket.
15.Fit fuse box, ensure harness routing is clear
suspension turret. Tighten nuts to 10 Nm (7
lbf.ft).
16.Fit fuse box cover.
17.Fit 'E' box housing into securing brackets.
18.Fit and tighten nut securing housing.
19.Fit harness and air duct rubber sleeve's to
housing.
20.Fit harness cable tie and secure relay in
housing.
21.Connect and secure joint harness and cooling
fan multiplugs.
22.Connect cooling fan sensor and gearbox ECU
multiplugs.
23.Fit ECM into 'E' box.

+ ENGINE MANAGEMENT SYSTEM -
EDC, REPAIRS, Engine control module
(ECM).
24.Position PTC positive cable to battery and
secure with bolt, tighten to 25 Nm (18 lbf.ft).
25.Connect battery earth lead.