Freelander Body Repair Manual — part 67
PANEL REPAIRS
REPAIRS
3
BONNET LOCKING PLATFORM
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator.
See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove front bumper valance.
See BODY,
Exterior fittings.
5. Remove radiator.
See COOLING SYSTEM,
Repairs.
6. Remove both headlamp assemblies.
See
ELECTRICAL, Repairs.
7. Remove horn.
See ELECTRICAL, Repairs.
8. Remove battery.
See ELECTRICAL, Repairs.
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.
See
ELECTRICAL, Repairs.
5. Fit horn.
See ELECTRICAL, Repairs.
6. Fit both headlamp assemblies.
See
ELECTRICAL, Repairs.
7. Fit radiator.
See COOLING SYSTEM,
Repairs.
8. Fit front bumper valance.
See BODY, Exterior
fittings.
9. Connect all ECUs.
10. Connect alternator.
See ELECTRICAL,
Repairs.
11. Connect battery earth lead.
PANEL REPAIRS
4
REPAIRS
HEADLAMP MOUNTING PANEL
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator.
See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove front bumper valance.
See BODY,
Exterior fittings.
5. Remove front bumper armature.
6. Remove radiator.
See COOLING SYSTEM,
Repairs.
7. Remove headlamp assembly.
See
ELECTRICAL, Repairs.
8. Release wiring to headlamp and position aside.
For LH side
9. Remove front bumper LH support bracket.
10. Remove battery.
See ELECTRICAL, Repairs.
11. Remove horn.
See ELECTRICAL, Repairs.
12. Remove air intake hose.
For RH side
13. Remove front bumper RH support bracket.
14. Remove windscreen washer reservoir.
See
WIPERS & WASHERS, Repairs.
15. Remove PAS fluid cooler.
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.
Refit
For LH side
1. Fit air intake hose.
2. Fit horn.
See ELECTRICAL, Repairs.
3. Fit battery. Do not connect earth lead.
See
ELECTRICAL, Repairs.
4. Fit front bumper LH support bracket.
For RH side
5. Fit PAS fluid cooler.
See STEERING,
Repairs.
6. Fit windscreen washer reservoir.
See WIPERS
& WASHERS, Repairs.
7. Fit front bumper LH support bracket.
For both sides
8. Fit headlamp assembly.
See ELECTRICAL,
Repairs. Secure headlamp wiring.
9. Fit radiator.
See COOLING SYSTEM,
Repairs.
10. Fit front bumper armature.
11. Fit front bumper valance.
See BODY, Exterior
fittings.
12. Connect all ECUs.
13. Connect alternator.
See ELECTRICAL,
Repairs.
14. Connect battery earth lead.
PANEL REPAIRS
REPAIRS
5
FRONT LOWER CROSSMEMBER
NOTE: In this procedure, the
crossmember to sidemember gusset
plates are replaced in conjunction with the
front lower crossmember.
If required, the lower closing panel can be
replaced separately.
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator.
See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove LH and RH engine bay shields.
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. Release wiring for LH and RH headlamps 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 wiring to LH and RH headlamps.
2. Fit PAS fluid cooler.
See STEERING,
Repairs.
3. Fit radiator.
See COOLING SYSTEM,
Repairs.
4. Fit front bumper armature.
5. Fit front bumper valance.
See BODY, Exterior
fittings.
6. Fit LH and RH engine bay shields.
7. Connect all ECUs.
8. Connect alternator.
See ELECTRICAL,
Repairs.
9. Connect battery earth lead.
PANEL REPAIRS
6
REPAIRS
FRONT SIDEMEMBER (COMPLETE)
NOTE: 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 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 suspension rear beam.
14. Remove engine and gearbox.
See ENGINE,
Repairs.
15. Remove PAS rack.
See STEERING, Repairs.
16. Remove fascia.
See BODY, Interior trim
components.
For LH side
17. Remove front bumper LH support bracket.
18. Remove LH engine mounting from body.
19. Remove battery.
See ELECTRICAL, Repairs.
20. Remove air intake hose.
21. Remove horn.
See ELECTRICAL, Repairs.
For RH side
22. Remove front bumper RH support bracket.
23. Remove RH engine mounting from body.
24. Remove windscreen washer reservoir.
See
WIPERS & WASHERS, Repairs.
For driver’s side
25. Remove passenger compartment fuse box.
26. Remove brake pedal box and brake servo.
See
BRAKES, Repairs.
27. Remove clutch pedal box.
See CLUTCH,
Repairs.
For both sides
28. Remove treadplate from front door aperture.
Release front carpet and position aside.
29. 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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