Freelander Body Repair Manual — part 68
PANEL REPAIRS
REPAIRS
7
Refit
1. Fit insulation pads to engine bulkhead.
2. Position front carpet and fit treadplate to front
door aperture.
For driver’s side
3. Fit clutch pedal box.
See CLUTCH, Repairs.
4. Fit brake pedal box and brake servo.
See
BRAKES, Repairs.
5. Fit passenger compartment fuse box.
For LH side
6. Fit horn.
See ELECTRICAL, Repairs.
7. Fit air intake hose.
8. Fit battery. Do not connect battery earth lead.
See ELECTRICAL, Repairs.
9. Fit LH engine mounting to body.
10. Fit front bumper LH support bracket.
For RH side
11. Fit windscreen washer reservoir.
See WIPERS
& WASHERS, Repairs.
12. Fit RH engine mounting to body.
13. Fit front bumper RH support bracket.
For both sides
14. Fit fascia.
See BODY, Interior trim
components.
15. Fit PAS rack.
See STEERING, Repairs.
16. Fit engine and gearbox.
See ENGINE,
Repairs.
17. Fit front suspension rear beam.
18. Fit front wheel arch liner.
See BODY, Exterior
fittings.
19. Fit engine bay shield.
20. Fit headlamp.
See ELECTRICAL, Repairs.
Secure headlamp wiring.
21. Fit PAS fluid cooler.
See STEERING,
Repairs.
22. Fit radiator.
See COOLING SYSTEM,
Repairs.
23. Fit front bumper armature.
24. Fit front bumper valance.
See BODY, Exterior
fittings.
25. Fit underbelly panel.
See BODY, Exterior
fittings.
26. Fit road wheel(s) and tighten nuts to correct
torque.
See INFORMATION, Torque wrench
settings.
27. Connect all ECUs.
28. Connect battery earth lead.
PANEL REPAIRS
8
REPAIRS
FRONT SIDEMEMBER (FRONT SECTION)
NOTE: In this procedure, the front section
of 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 all ECUs.
3. Remove road wheel(s).
4. Remove underbelly panel.
See BODY,
Exterior fittings.
5. Remove front bumper valance.
See BODY,
Exterior fittings.
6. Remove radiator.
See COOLING SYSTEM,
Repairs.
7. Remove PAS fluid cooler.
See STEERING,
Repairs.
8. Remove headlamp.
See ELECTRICAL,
Repairs.
9. Release wiring to headlamp and position aside.
10. Remove engine bay shield.
11. Remove front wheel arch liner.
See BODY,
Exterior fittings.
For LH side
12. Remove front bumper LH support bracket.
13. Remove ECM.
14. Remove battery carrier.
See ELECTRICAL,
Repairs.
15. Remove air cleaner.
16. Remove air intake hose.
17. Remove horn.
See ELECTRICAL, Repairs.
For RH side
18. Remove front bumper RH support bracket.
19. Remove windscreen washer reservoir.
See
WIPERS & WASHERS, Repairs.
20. Remove alternator.
See ELECTRICAL,
Repairs.
21. Remove PAS pump.
See STEERING,
Repairs.
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
REPAIRS
9
Refit
For LH side
1. Fit horn.
See ELECTRICAL, Repairs.
2. Fit air intake hose.
3. Fit air cleaner.
4. Fit battery carrier. Do not connect battery earth
lead.
See ELECTRICAL, Repairs.
5. Fit ECM.
6. Fit front bumper LH support bracket.
For RH side
7. Fit PAS pump.
See STEERING, Repairs.
8. Fit alternator.
See ELECTRICAL, Repairs.
9. Fit windscreen washer reservoir.
See WIPERS
& WASHERS, Repairs.
10. Fit front bumper RH support bracket.
For both sides
11. Fit front wheel arch liner.
See BODY, Exterior
fittings.
12. Fit engine bay shield.
13. Fit headlamp.
See ELECTRICAL, Repairs.
Secure headlamp wiring.
14. Fit PAS fluid cooler.
See STEERING,
Repairs.
15. Fit radiator.
See COOLING SYSTEM,
Repairs.
16. Fit front bumper valance.
See BODY, Exterior
fittings.
17. Fit underbelly panel.
See BODY, Exterior
fittings. See
18. Connect all ECUs.
19. Connect battery earth lead.
PANEL REPAIRS
10
REPAIRS
FRONT VALANCE ASSEMBLY
Remove
1. Disconnect battery earth lead.
2. Disconnect all ECUs.
3. Remove road wheel(s).
4. Remove underbelly panel.
See BODY,
Exterior fittings.
5. Remove front bumper valance.
See BODY,
Exterior fittings.
6. Remove front bumper armature.
7. Remove radiator.
See COOLING SYSTEM,
Repairs.
8. Remove PAS fluid cooler.
See STEERING,
Repairs.
9. Remove headlamp.
See ELECTRICAL,
Repairs.
10. Release wiring to headlamp and position aside.
11. Remove engine bay shield.
12. Remove front wheel arch liner.
See BODY,
Exterior fittings.
13. Remove front wing.
See BODY, Exterior
fittings.
14. Remove front suspension rear beam.
15. Remove engine and gearbox.
See ENGINE,
Repairs.
16. Remove front damper.
See FRONT
SUSPENSION, Repairs.
17. Remove PAS rack.
See STEERING, Repairs.
18. Remove fascia.
See BODY, Interior trim
components.
For LH side
19. Remove front bumper LH support bracket.
20. Remove tool kit.
21. Remove air cleaner.
22. Remove air intake hose.
23. Remove ECM.
24. Remove relay module.
See ELECTRICAL,
Repairs.
25. Remove battery carrier.
See ELECTRICAL,
Repairs.
26. Remove engine compartment fuse box and
related wiring.
27. Remove LH engine mounting from body.
28. On models with ’L’ series engine, remove fuel
filter.
See FUEL DELIVERY SYSTEM - ’L’
SERIES, Repairs.
29. Remove LH front brake pipe.
For RH side
30. Remove front bumper RH support bracket.
31. Remove windscreen washer reservoir.
See
WIPERS & WASHERS, Repairs.
32. Remove coolant expansion tank.
See
COOLING SYSTEM, Repairs.
33. Remove RH engine mounting from body.
34. Remove PAS fluid reservoir.
See STEERING,
Repairs.
35. Remove RH front brake pipe.
36. Remove pressure conscious reducing valve
and related brake pipes.
See BRAKES,
Repairs.
For driver’s side
37. Remove passenger compartment fuse box.
38. Remove brake pedal box and brake servo.
See
BRAKES, Repairs.
39. Remove clutch pedal box.
See CLUTCH,
Repairs.
For both sides
40. Release vehicle harness from valance and
position aside.
41. Remove treadplate from front door aperture.
Release front carpet and position aside.
42. Remove insulation pads from engine bulkhead.
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.
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