2001 LAND ROVER FREELANDER Workshop Manual

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.

HEATING AND VENTILATION
REPAIRS 80-1
HEATING A ND VENT ILATION REPAIRS
Controls - heater - up to 04MY
$% 80.10.02
Remove
1.Remove front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
2.Release air blend control cable from control
knob and abutment.
3.Release air distribution control cable from
control knob and abutment.
4.Disconnect multiplugs from all switches.
5.Disconnect illumination multiplug.
6.Remove heater controls.
7.Remove fan speed switch drive shaft.8.Remove 2 screws securing fan speed switch
and remove switch.
9.Remove 5 switches from heater controls.
Refit
1.Fit switches to heater control housing.
2.Fit fan speed switch and secure with screws.
3.Fit drive shaft to fan speed switch.
4.Fit heater control assembly to vehicle.
5.Connect switch and illumination multiplugs.
6.Connect air blend control cable to control knob
and abutment.
7.Connect air distribution control cable to control
knob and abutment.
8.Fit front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.

HEATING AND VENTILATION
80-2REPAIRS
Controls - heater - from 04MY
$% 80.10.02
Remove
1.Remove the Radio/CD module.

+ IN CAR ENTERTAINMENT,
REPAIRS, Radio/CD - from 04MY.
2.Remove 4 screws securing heater controls to
fascia.
3.Move heater control assembly to access
cables.
4.Release air distribution cables from control
knobs and abutments.
5.Disconnect 3 multiplugs from heater control
assembly.
6.Remove heater controls.Refit
1.Fit heater control assembly to vehicle.
2.Connect multiplugs.
3.Connect heater control cables and secure to
abutment with clips.
4.Position heater control panel, fit and tighten
screws.
5.Fit Radio/CD module.
+ IN CAR ENTERTAINMENT,
REPAIRS, Radio/CD - from 04MY.
M80 0578

HEATING AND VENTILATION
REPAIRS 80-3
Servo - air recirculation
$% 80.10.18
Remove
1.Remove glove box.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Glove box.
2.Disconnect multiplug from servo.
3.Remove screw securing servo to evaporator
and remove servo.
Refit
1.Fit servo to evaporator and secure with screw.
2.Connect multiplug to servo.
3.Fit glove box.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Glove box.
Switch - recirculation control
$% 80.10.21
Remove
1.Remove 3 heater control knobs.
2.Remove 2 screws securing heater control
finisher to heater controls and remove finisher.
3.Release switch and disconnect multiplug.
4.Remove switch.
Refit
1.Fit recirculation switch to heater control panel
and connect multiplug.
2.Fit heater control finisher to heater controls and
secure with screws.
3.Fit heater control knobs.

HEATING AND VENTILATION
80-4REPAIRS
Switch - fan - front heater
$% 80.10.22
Remove
1.Remove front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
2.Disconnect multiplug from switch.
3.Remove drive shaft from switch.4.Remove 2 screws securing switch to heater
controls.
5.Remove switch.
Refit
1.Fit switch to heater controls and secure with
screws.
2.Fit drive shaft to switch.
3.Connect multiplug to switch.
4.Fit front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.

HEATING AND VENTILATION
REPAIRS 80-5
Ventilator - face level - LH
$% 80.15.05
Remove
1.Protect fascia and carefully lever vent from
fascia.
2.Remove and discard seal.Refit
1.Fit new seal to vent.
2.Fit vent to fascia.

HEATING AND VENTILATION
80-6REPAIRS
Plenum - air intake
$% 80.15.62
Remove
1.Remove both wiper arms.

+ WIPERS AND WASHERS, REPAIRS,
Arm - wiper - each.
2.Remove 6 studs securing rear edge of air
intake moulding.
3.Remove air intake moulding and bonnet
sealing rubber.
NOTE: Do not carry out further dismantling if
component is removed for access only.
4.Remove bonnet sealing rubber from air intake
moulding.
5.Remove 4 clips securing air intake filter
retainers. Remove retainers and filters.Refit
1.Fit filters and retainers to air intake moulding
and secure with clips.
2.Fit bonnet sealing rubber to air intake moulding.
3.Fit air intake moulding and secure with studs.
4.Fit wiper arms.

+ WIPERS AND WASHERS, REPAIRS,
Arm - wiper - each.

HEATING AND VENTILATION
REPAIRS 80-7
Heater unit
$% 80.20.01
Remove
1.Drain cooling system.

+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.

+ COOLING SYSTEM - K SERIES 1.8,
ADJUSTMENTS, Coolant - drain & refill.

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
2.Release 2 clips securing heater hoses to heater
and disconnect hoses.
3.Remove fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
4.Remove 2 bolts from console support bracket,
release 2 relays and remove bracket. Up to
03MY illustrated.5.Disconnect 4 multiplugs from heater controls.
Up to 04MY illustrated.
6.Disconnect multiplug from heater and release
diagnostic socket.
7. Models with A/C: Disconnect multiplug from
evaporator.
8.Remove bolt from duct of LH outer face level
vent and release duct from heater.