2001 LAND ROVER FREELANDER headlamp

PANEL REPAIRS
TIMES 77-2-63
TIME S
TIME SCHEDULES
The following information shows the total time taken to replace single panels and complete assemblies. This time
includes removal of Mechanical, Electrical and Trim (MET) items, plus paint times based on Metallic Clear Over Base
Paint.
The times shown were generated by Thatcham (the Motor Insurance Repair and Research Centre) and are to be used
as a guide only.
Panel/assembly panel replacement times 5 Door
Panel Description Total time
Body side LH 29.4
Body side RH 31.5
Bonnet 7.2
Bonnet locking platform 7.0
Door front - each 8.4
Door rear - each 8.1
Door skin front - each 12.2
Door skin rear - each 11.2
Front bulkhead assembly 12.7
Front lower crossmember 8.5
Headlamp mounting panel 6.4
Rear floor crossmember assembly 9.5
Roof assembly 23.5
Bodyside lower outer LH 16.8
Bodyside lower outer RH 16.9
Taildoor 9.0
Wing6.9
Bodyside rear outer LH 19.3
Bodyside rear outer RH 21.5

PANEL REPAIRS
77-2-64 TIMES
Combination panel replacement times
The following panel combination times show the total time to remove/refit body panels, MET items and any paint
processes.
5 Door - Front end combination panel times
Panel Description Total Time
Bonnet locking platform
Bumper front
Headlamp mounting panel
Wing
15.3
Bumper front
Front Panel assembly
Wing RH & LH
20.6
Bonnet locking platform
Bumper front
Sidemember closing panel
Sidemember front section
Front crossmember lower
Headlamp mounting panel
Wing
Valance upper assembly section
Valance outer reinforcement section
35.7 LH
37.9 RH
Bumper front
Sidemember closing panel LH front
Sidemember closing panel RH front
Sidemember complete assembly LH
Sidemember complete assembly RH
Front bulkhead assembly
Wing LH & RH
Valance upper assembly LH & RH
Valance outer reinforcement section LH & RH
49.1
Bonnet locking platform
Bumper front
Sidemember closing panel section
Sidemember front section
Front crossmember lower
Headlamp mounting panel
Valance front section
Wing
Valance upper assembly section
Valance outer reinforcement section
27.1 LH
27.7 RH

PAINTING
77-5-2 PAINT PROCEDURES
Paint preparation
Paint refinishing
The following process must be adhered to for paint refinishing operations.
1Seal required exterior and interior seams with an approved seam sealer

+ , , .
2Repair any damage to underbody sealers

+ , , Corrosion Prevention.
3Apply a two-pack paint refinishing system
4Apply cavity wax to all interior surfaces which have not received refinish paint
Paint repairs
Before carrying out paintwork repairs, clean the vehicle thoroughly using either a steam cleaner or high-pressure
washer.
Wash locally repaired areas using a mild water-mixable detergent and wipe them clean with solvent, immediately
before paint application.
Ensure that damaged paintwork which has led to exposed metal is abraded until the metal is clean, extending beyond
the area of the original damage. Treat the bare metal with an etch phosphate to remove all traces of rust and to provide
a key for new paint coats. Re-treat the affected area using either a separate acid-etch primer and two-pack surfacer
or an integrated etch primer/filler, and follow with a two-pack paint system. Treat those surfaces not receiving paint
using an approved cavity wax, following paint operations.
aTwo-pack top coat
bTwo-pack primer filler and etch primer
cEtch phosphate
When heat curing paint repairs, the temperature must not exceed 65°C (149°F). Temperatures above this
figure will cause the reflective elements within the headlamps and tail lamps to distort and may damage other
components.

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.

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.

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

LIGHTING
REPAIRS 86-2-9
Switch - headlamp levelling
$% 86.65.16
Remove
1.Release headlamp levelling switch from fascia
and disconnect multiplug.
Refit
1.Position switch, connect multiplug and secure
switch to fascia.
Switch - glove compartment
$% 86.65.24
Remove
1.Remove glove box.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Glove box.
2.Disconnect 2 Lucars from glove box lamp
switch.
3.Release clips and remove switch from glove
box latch.
Refit
1.Fit switch to glove box latch and connect
Lucars.
2.Fit glove box.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Glove box.

HARNESSES
86-7-2 REPAIRS
Harness - main
$% 86.70.07
Remove
1.Make the SRS system safe.

+ GENERAL INFORMATION,
Supplementary restraint system
precautions.
2.Remove carpet.
3.Remove engine acoustic cover.

+ ENGINE - Td4, REPAIRS, Cover -
engine acoustic - Up to 02.5 Model Year.
4.Remove windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
5.Pull reservoir harness and washer tubes into
engine bay.
6.Remove nut and release earth header from RH
inner wing.
7.Disconnect multiplug from ABS modulator.
8.Disconnect multiplug from RH ABS speed
sensor and release harness from clips.
9.Disconnect 2 multiplugs from RH headlamp
and headlamp levelling motor.10.Disconnect multiplugs from horn, refrigerant
pressure sensor and compressor.
11.Remove jack from holder in engine bay.
12.Disconnect multiplug from brake fluid low level
indicator switch.
13.Disconnect multiplug from bonnet switch.
14.Remove bolt and 2 nuts securing PAS and
coolant reservoir support bracket and position
aside.
15.Release 5 harness retaining clips.
16.Release front screen wash tube from harness
and position aside.
17.Remove nut securing earth header to bulk head
and remove earth header.