2001 LAND ROVER FREELANDER brake

CORROSION PREVENTION AND SEALING
CORROSION PREVENTION 77-4-5
Corrosion Prevention
The following information details Corrosion Prevention treatments.
Factory treatments
During production, vehicle bodies are treated with the following anti-corrosion materials:
lAn application of cavity wax which is sprayed into the sill panels and the lower areas of the door panels.
lA PVC-based underbody sealer which is sprayed onto the underside of the main floor and sills, the exterior of
the safe well and the forward face of the lower dash crossmember.
lA coating of underbody wax which is applied to the entire underbody inboard of the sill vertical flanges, and
covers all moving and flexible components EXCEPT for wheels, tyres, brakes and exhaust.
lA coat of protective wax applied to the engine bay area.
Whenever body repairs are carried out, ensure the anti-corrosion materials in the affected area are repaired or
renewed as necessary using the approved materials.
Cavity wax injection
Areas treated with cavity wax are shown in the following Figures. After repairs, always re-treat these areas with an
approved cavity wax. In addition, treat all interior surfaces which have been disturbed during repairs whether they
have been treated in production or not. This includes all box members, cavities and door interiors. It is permissible to
drill extra holes for access where necessary, provided these are not positioned in load-bearing members. Ensure that
such holes are treated with a suitable zinc rich primer, brushed with wax and then sealed with a rubber grommet.
Before wax injection, ensure that the cavity to be treated is free from any contamination or foreign matter. Where
necessary, clear out any debris using compressed air.
Ensure that cavity wax is applied AFTER the final paint process and BEFORE refitting any trim components.
During application, ensure that the wax covers all flange and seam areas and that it is adequately applied to all
repaired areas of both new and existing panels.
It should be noted that new panel assemblies and complete body shells are supplied without wax injection treatment.
Ensure that such treatment is carried out after repairs.
Effective cavity wax protection is vital. Always observe the following points:
lComplete all paint refinish operations before wax application.
lClean body panel areas and blow-clean cavities if necessary, before treatment.
lMaintain a temperature of 18°C during application and drying.
lCheck the spray pattern of injection equipment.
lMask off all areas not to be wax coated and which could be contaminated by wax overspray.
lRemove body fixings, such as seat belt retractors, if contamination is at all likely.
lMove door glasses to fully closed position before treating door interiors.
lTreat body areas normally covered by trim before refitting items.
lCheck that body and door drain holes are clear after the protective wax has dried.
lKeep all equipment clean, especially wax injection nozzles.

CORROSION PREVENTION AND SEALING
77-4-8 SEALING
Underbody sealer
Underfloor areas and sill outer panels are treated with a Plastisol PVC underbody sealer. This material is not suitable
for re-treatment. When repairing areas of underbody sealer, strip the factory-applied underbody sealer back to a
suitable break point. Ensure that a clean metal surface is exposed and that the edge of the existing sealer adheres
soundly to the panel.
Apply new underbody sealer between primer and surfacer paint operations. Apply seam sealer as necessary before
application of underbody sealer. Ensure that blanking plugs and grommets in the floor pan (except those used for wax
injection) are fitted before underbody sealer application. Refit any heat-fusible plugs which have been disturbed in
repair with the aid of a hot air blower, or replace with rubber grommets.
caut : Ensure that suspension units, wheels, tyres, power unit, driveshafts, exhaust and brakes (including all mounting
points) are shielded prior to application of fresh underbody sealer.
Underbody wax
The underbody wax must be reinstated following all repairs affecting floor panels. The wax is applied over paints and
underbody sealers.
caut : Remove old underbody wax completely from a zone extending at least 200mm beyond the area where new
underbody sealer is to be applied.
Engine bay wax
Reinstate all protective engine bay wax disturbed during repairs using an approved material.
Where repairs have involved replacement of engine bay panels, treat the entire engine compartment including all
components, clips and other fixtures with an approved underbonnet lacquer or wax.
Precautions during body repairs and handling
Take care when handling the vehicle in the workshop. Underbody sealers, seam sealers, underbody wax and body
panels may be damaged if the vehicle is carelessly lifted.
Proprietary anti-corrosion treatments
The application of proprietary anti-corrosion treatments in addition to the factory-applied treatment could invalidate
the Corrosion Warranty and should be discouraged. This does not apply to approved, compatible, preservative waxes
which may be applied on top of existing coatings.
Fitting approved accessories
When fitting accessories ensure that the vehicle's corrosion protection is not affected, either by breaking the protective
coating or by introducing a moisture trap.
Do not screw self-tapping screws directly into body panels. Fit suitable plastic inserts to the panel beforehand. Always
ensure that the edges of holes drilled into panels, chassis members and other body parts are protected with a suitable
zinc rich or acid etch primer, and follow with a protective wax coating brushed onto the surrounding area.
Do not attach painted metal surfaces of any accessory directly to the vehicle's bodywork unless suitably protected.
Where metal faces are bolted together always interpose a suitable interface material such as weldable zinc rich
primer, extruded strip, or zinc tape.
Steam cleaning and dewaxing
Due to the high temperatures generated by steam cleaning equipment, there is a risk that certain trim components
could be damaged and some adhesives and corrosion prevention materials softened or liquified.
Adjust the equipment so that the nozzle temperature does not exceed 90°C (194°F). Take care not to allow the steam
jet to dwell on one area, and keep the nozzle at least 300mm from panel surfaces.
DO NOT remove wax or lacquer from underbody or underbonnet areas during repairs. Should it be necessary to
steam clean these areas, apply a new coating of wax or underbody protection as soon as possible.

CORROSION PREVENTION AND SEALING
77-4-10 SEALING
Underbody protection repairs
Whenever body repairs are carried out, ensure that full sealing and corrosion protection treatments are reinstated.
This applies both to the damaged areas and also to areas where protection has been indirectly impaired, as a result
either of accident damage or repair operations.
Remove corrosion protection from the damaged area before straightening or panel beating. This applies in particular
to panels coated with wax, PVC underbody sealer, sound deadening pads etc.
warn : DO NOT use oxy-acetylene gas equipment to remove corrosion prevention materials. Large volumes of fumes
and gases are liberated by these materials when they burn.
Equipment for the removal of tough anti-corrosion sealers offers varying degrees of speed and effectiveness. The
compressed air-operated scraper (NOT an air chisel) offers a relatively quiet mechanical method using an extremely
rapid reciprocating action. Move the operating end of the tool along the work surface to remove the material.
The most common method of removal is by means of a hot air blower with integral scraper.
High temperatures can be generated with this equipment which may cause fumes. Take care during its use.
Another tool, and one of the most efficient methods, is the rapid-cutting 'hot knife'. This tool uses a wide blade and is
quick and versatile, able to be used easily in profiled sections where access is otherwise difficult.
Use the following procedure when repairing underbody coatings:
1Remove existing underbody coatings.
2After panel repair, clean the affected area with a solvent wipe, and treat bare metal with an etch phosphate
material.
3Re-prime the affected area.
caut: DO NOT, under any circumstances, apply underbody sealer directly to bare metal surfaces.
lReplace all heat-fusible plugs which have been disturbed. Where such plugs are not available use rubber
grommets of equivalent size, ensuring that they are embedded in sealer.
lMask off all mounting faces from which mechanical components, hoses and pipe clips, have been removed.
Underbody sealer must be applied before such components are refitted.
lBrush sealer into all exposed seams.
lSpray the affected area with an approved service underbody sealer.
lRemove masking from component mounting faces, and touch-in where necessary. Allow adequate drying time
before applying underbody wax.
After refitting mechanical components, including hoses and pipes and other fixtures, mask off the brake discs and
apply a coat of approved underbody wax.
note : Where repairs include the application of finish paint coats in the areas requiring underbody wax, carry out paint
operations before applying wax.
STRUCTURAL ADHESIVES
Metal-to-metal adhesive is applied to critical joint areas during factory assembly. The material used is a high-
temperature, heat cured, nitrile phenolic which serves to bond two metal surfaces and also to seal the joint against
ingress of dust, moisture and fumes. This material is not suitable for service use and, during repair, should be
substituted by an approved Structural Adhesive.
Those joints which require the application of structural adhesive are detailed in the following Figures. Only joints
applicable to service panels are included. Apply structural adhesive where indicated or to the mating panel surface.
caut : When separating a joint treated with metal-to-metal adhesive, it is important to avoid distortion. Heat the joint
gradually until the bond weakens sufficiently to permit panel separation.
note : When spot welding through metal-to-metal adhesive, take particular care to adjust the transformer setting to
ensure a reliable weld.

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.

HARNESSES
86-7-6 REPAIRS
53.Release fuse box, disconnect 11 multiplugs
and remove fuse box.
54.Disconnect multiplug from steering column
switch.
55.Release harness clip from steering column.
56.Disconnect multiplug from throttle position
sensor.
57.Disconnect multiplugs from brake light switch
and brake pedal position switch.58.Disconnect multiplug from airbag ECU.
59.Remove airbag ECU securing bolt and release
earth lead.
60.Remove nut from earth header and release
header from floor tunnel.

HARNESSES
REPAIRS 86-7-7
61.Disconnect heated oxygen sensor multiplug.
62. Automatic gearbox only: Disconnect
multiplugs from gear selector.
63.Disconnect multiplug from accelerometer.
64. Manual gearbox only: Disconnect multiplug
from gear lever hill descent switch.
65.Disconnect Lucar from handbrake switch.
66.Release 2 relays from bracket and remove
bracket.
67.Release 4 clips securing harness to air ducting.
68.Remove nut from rear heater ducting and
remove ducting.
69.Remove 4 nuts securing steering column to
bracket and lower column.
70.Remove face level vent ducting to access main
harness clips.71.Disconnect multiplug from window lift ECU.
72.Remove nut securing earth header to RH 'A'
post and release header.
73.Release multiplugs and earth header from LH
lower 'A' post.

HARNESSES
86-7-10 REPAIRS
90.Remove 4 screws from rear bumper lamps,
release lamps and disconnect multiplugs.
91.Release harness clips and pull harness into
luggage compartment.
92.Release main harness retaining clips and pull
harness into vehicle interior.
93.Remove main harness.Refit
1.Lay main harness in vehicle.
2.Locate rear section and secure in retaining
clips.
3.Feed harness to rear bumper lamps, secure in
clips and grommets.
4.Connect multiplugs to rear bumper lamps, fit
rear lamps and secure with screws.
5.Fit LH rear earth header and secure with nut.
6.Connect multiplugs to LH tail lamp.
7.Position RH tail lamp and connect multiplugs.
8.Fit RH tail lamp and secure with Torx screws.
9.Fit RH rear earth header and secure with nut.
10.Connect multiplug to towing electrics.
11.Connect rear screen washer tube.
12.Connect tail door harness multiplugs.
13.Connect and fit rear window lift and wash/wipe
relays.
14.Position harness into luggage compartment.
15.Connect both rear ABS speed sensor
multiplugs and secure harness grommets.
16.Connect multiplug to fuel pump.
17.Fit fuel pump access cover and secure with
screws.
18.Fit luggage compartment carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
19.Connect multiplugs at the base of 'B/C' Posts.
20.Fit all harness clips to interior of vehicle.
21.Fit multiplugs and earth header to LH lower 'A'
post.
22.Fit earth header to RH lower 'A' post.
23.Connect multiplug to window lift ECU.
24.Fit face level vent ducting.
25.Fit steering column to bracket and secure with
nuts.
26.Fit rear heater ducting and secure with nut.
27.Secure harness to rear heater ducting with
clips.
28.Position mounting bracket and secure relays.
29.Connect Lucar to handbrake switch.
30. Manual gearbox only: Connect multiplug to
gear lever hill descent switch.
31.Connect multiplug to accelerometer.
32. Automatic gearbox only: Connect multiplugs
to gear selector.
33.Connect heated oxygen sensor multiplug.
34.Fit earth header to floor tunnel and secure with
nut.
35.Fit earth lead to airbag ECU and secure with
bolt.
36.Connect multiplug to airbag ECU.
37.Connect multiplugs to brake light switch and
brake pedal position switch.
38.Connect multiplug to throttle position sensor.
39.Fit harness clip to steering column.
40.Connect multiplug to steering column switch.

HARNESSES
REPAIRS 86-7-11
41.Position fuse box to body and connect
multiplugs.
42.Fit relays to fuse box bracket.
43.Connect coaxial cable.
44.Fit and connect multiplug to RH 'A' post.
45.Fit passenger compartment fuse box and
secure with bolts.
46.Position side repeater lamps, connect
multiplugs and fit to wings.
47.Secure rear edge of front wheel arch liners.
48.Fit front mud flaps and secure with screws.
49.With assistance feed harness through bulk
head into engine bay.
50.Position harness to wiper motor and connect
multiplug.
51.Fit air intake plenum.

+ HEATING AND VENTILATION,
REPAIRS, Plenum - air intake.
52.Secure harness to LH side of engine bay and
secure fixings.
53.Connect multiplug to inertia switch.
54.Connect multiplugs to underside of fuse box.
55.Fit nuts securing fuse box to brackets.
56.Fit battery connections and multiplug to fuse
box.
57.Fit fuse box cover.
58.Connect 'E' box cooling fan multiplug.
59.Connect 'E' box temperature sensor multiplug.
60.Connect engine harness multiplugs to main
harness.
61. Automatic gearbox only:Connect multiplug to
gearbox ECU.
62.Fit 'E' box cover and secure with Allen screws.
63.Connect engine harness multiplugs to main
harness.
64.Fit harness retaining clips.
65. Models with cruise control: Connect
multiplug to vacuum pump.
66.Connect Lucar connector to starter motor.
67.Connect multiplug to LH ABS speed sensor.
68.Fit LH earth header and secure with nut.
69.Connect multiplug to harness.
70.Connect multiplugs to LH headlamp and
headlamp levelling motor.
71.Secure harness to cooling fan clips.
72.Connect multiplugs to cooling fan pack and
cooling fans.
73.Position bonnet release cable to harness and
secure with cable ties.
74.Fit battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
75.With assistance feed harness through bulk
head into engine bay.
76.Fit earth header to bulk head and secure with
nut.
77.Fit front screen washer tube to harness.
78.Fit harness retaining clips.79.Fit PAS and coolant reservoir support bracket
and secure with bolt and nuts.
80.Connect multiplug to bonnet switch.
81.Connect multiplug to brake fluid low level
indicator switch.
82.Fit jack to holder in engine bay.
83.Connect multiplugs to horn, refrigerant
pressure sensor and compressor.
84.Connect multiplugs to RH headlamp and
headlamp levelling motor.
85.Connect multiplug to RH ABS speed sensor
and secure to clips.
86.Connect multiplug to ABS modulator.
87.Fit earth header to RH inner wing and secure
with nut.
88.Position harness to windscreen washer
reservoir.
89.Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
90.Fit engine acoustic cover.

+ ENGINE - Td4, REPAIRS, Cover -
engine acoustic - Up to 02.5 Model Year.
91.Fit carpet.