2001 LAND ROVER FREELANDER Workshop Manual

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.

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.

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
77-2-58 REPAIRS
Rear floor crossmember assembly
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove tail door.

+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
5.Remove tail door aperture seal.
6.Remove LH and RH rear quarter lower casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
7.Remove loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
8.Release vehicle harness from rear body lower
closing and position aside.
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.Secure vehicle harness to rear body lower
closing.
2.Fit loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
3.Fit LH and RH rear quarter lower casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
4.Fit tail door aperture seal.
5.Fit tail door.

+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
6.Connect all ECUs.
7.Connect alternator.
8.Connect battery earth lead.

PANEL REPAIRS
REPAIRS 77-2-59
Rear floor
In this procedure, the inner quarter to rear floor
gussets are replaced in conjunction with the rear
floor. If required, the safe well can be replaced
separately.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove tail exhaust pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - tail.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES 1.8, REPAIRS, Exhaust pipe -
tail.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Tail pipe &
silencer.
5.Remove tail door.

+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
6.Remove tail door aperture seal.
7.Remove LH and RH rear quarter lower casings.

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

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
9.Remove fuel tank.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.
10.Release vehicle harness from rear body lower
closing and position aside. 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.Secure vehicle harness to rear body lower
closing.
2.Fit fuel tank.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.
3.Fit loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
4.Fit LH and RH rear quarter lower casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
5.Fit tail door aperture seal.
6.Fit tail door.

+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
7.Fit tail exhaust pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - tail.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES 1.8, REPAIRS, Exhaust pipe -
tail.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Tail pipe &
silencer.
8.Connect all ECUs.
9.Connect alternator.
10.Connect battery earth lead.

PANEL REPAIRS
77-2-60 REPAIRS
Floor longitudinal
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove tail exhaust pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - tail.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES 1.8, REPAIRS, Exhaust pipe -
tail.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Tail pipe &
silencer.
5.Remove tail door.

+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
6.Remove tail door aperture seal.
7.Remove LH and RH rear quarter lower casings.

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

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
9.Remove fuel tank.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.
10.Release vehicle harness from rear body lower
closing and position aside. 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.Secure vehicle harness to rear body lower
closing.
2.Fit fuel tank.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.
3.Fit loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
4.Fit LH and RH rear quarter lower casings.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
5.Fit tail door aperture seal.
6.Fit tail door.

+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
7.Fit tail exhaust pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - tail.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES 1.8, REPAIRS, Exhaust pipe -
tail.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Tail pipe &
silencer.
8.Connect all ECUs.
9.Connect alternator.
10.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.