2001 LAND ROVER FREELANDER headlamp

BODY DIMENSIONS
77-1-18 BODY GAPS AND PROFILES
Section Gap Description Dimension
D-D d Headlamp to wing 3.0 (0.118)
E-E e Bonnet to wing 6.0 (0.236)
F-F f Rear edge bonnet to wing 6.0 (0.236)
G-G g Wing to front door 5.0 (0.196)
H-H, J-J h Front door frame to body 5.0 (0.196)
K-K, L-L k Front door to rear door 5.0 (0.196)
M-M m Bottom of door to sill 6.0 (0.236)
N-N, P-P n Rear door to body 5.0 (0.196)

PANEL REPAIRS
REPLACEMENT PANELS 77-2-3
REPLACE ME NT PA NELS
Serviceable Panels
Front end panels
1Bonnet locking platform
2LH headlamp mounting panel
3Front lower crossmember assembly
4LH crossmember gusset plate
5RH crossmember gusset plate
6Front bulkhead assembly
7RH headlamp mounting panel
8Bonnet locking platform reinforcement

PANEL REPAIRS
REPAIRS 77-2-25
REPAIRS
Front bulkhead assembly
In this procedure, the crossmember gusset plates
are replaced in conjunction with the front bulkhead
assembly.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5.Remove front bumper armature.
6.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
7.Remove PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
8.Remove LH and RH headlamps.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
9.Release wiring to headlamps and position
aside.
10.Remove LH and RH engine bay shields.
11.Remove bumper valance LH and RH
attachment brackets.
12.Remove battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
13.Remove air intake hose.
14.Remove horn.

+ SECURITY, REPAIRS, Horn.
15.Remove windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
16.Remove bonnet lock.
17.Support bonnet in open position.
18.Remove bonnet stay. 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
77-2-26 REPAIRS
Refit
1.Fit bonnet stay.
2.Fit bonnet lock.
3.Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
4.Fit horn.

+ SECURITY, REPAIRS, Horn.
5.Fit air intake hose.
6.Fit battery. Do not connect earth lead.

+ CHARGING AND STARTING,
REPAIRS, Battery.
7.Fit bumper valance LH and RH attachment
brackets.
8.Fit LH and RH engine bay shields.
9.Fit LH and RH headlamps.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY. Secure headlamps
wiring.
10.Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
11.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
12.Fit front bumper armature.
13.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
14.Connect all ECUs.
15.Connect alternator.
16.Connect battery earth lead.

PANEL REPAIRS
REPAIRS 77-2-27
Bonnet locking platform
In this procedure the bonnet locking platform
reinforcement is also replaced in conjunction with the
bonnet locking platform.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
6.Remove both headlamp assemblies.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
7.Remove horn.

+ SECURITY, REPAIRS, Horn.
8.Remove battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
9.Remove air intake hose.
10.Remove bonnet lock.
11.Support bonnet in open position.
12.Remove bonnet stay.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Refit
1.Fit bonnet stay.
2.Fit bonnet lock.
3.Fit air intake hose.
4.Fit battery. Do not connect earth lead.

+ CHARGING AND STARTING,
REPAIRS, Battery.
5.Fit horn.

+ SECURITY, REPAIRS, Horn.
6.Fit both headlamp assemblies.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
7.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
8.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
9.Connect all ECUs.
10.Connect alternator.
11.Connect battery earth lead.

PANEL REPAIRS
77-2-28 REPAIRS
Headlamp mounting panel
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
5.Remove front bumper armature.
6.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
7.Remove headlamp assembly.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
8.Release wiring to headlamp and position aside.
9. LH side: Remove front bumper LH support
bracket.
10. LH side: Remove battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
11. LH side: Remove horn.

+ SECURITY, REPAIRS, Horn.
12. LH side: Remove air intake hose.
13. RH side: Remove front bumper RH support
bracket.
14. RH side: Remove windscreen washer
reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
15. RH side: Remove PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.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 air intake hose.
2. LH side: Fit horn.
3. LH side: Fit battery. Do not connect earth lead.

+ CHARGING AND STARTING,
REPAIRS, Battery.
4. LH side: Fit front bumper LH support bracket.
5. RH side: Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
6. RH side: Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
7. RH side: Fit front bumper LH support bracket.
8.Fit headlamp assembly.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.Secure headlamp
wiring.
9.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
10.Fit front bumper armature.
11.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
12.Connect all ECUs.
13.Connect alternator.
14.Connect battery earth lead.

PANEL REPAIRS
REPAIRS 77-2-29
Front lower crossmember
In this procedure, the crossmember gusset plates
are replaced in conjunction with the front lower
crossmember.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove LH and RH engine bay shields.
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.Release wiring for LH and RH headlamps and
position aside.
Repair1.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. The front lower crossmember assembly
is only supplied with a limited amount of
spotwelds. Ensure that the correct amount of
plug welds are put onto the assembly as a
substitute for the spotwelds, see illustration
below.
Refit
1.Secure wiring to LH and RH headlamps.
2.Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
3.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
4.Fit front bumper armature.
5.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
6.Fit LH and RH engine bay shields.
7.Connect all ECUs.
8.Connect alternator.
9.Connect battery earth lead.

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.