2001 LAND ROVER FREELANDER belt

PANEL REPAIRS
PROCEDURES 77-2-23
3.Use a resistance spot welder where access
permits. Try to ensure weld quality by using a
welding monitor where possible.
4.MIG tack weld butt joints and re-check
alignment and panel contours where
necessary. Ensure that a gap is maintained to
minimise welding distortion, by inserting a
hacksaw blade as an approximate guide.5.Dress MIG tack welds using a sander with 36
grit disc, or a belt-type sander where access is
limited.
6.MIG seam weld butt joints.

PANEL REPAIRS
77-2-24 PROCEDURES
7.Always use MIG plug welds where excessive
metal thickness or limited access make
resistance spot welding impractical. Make plug
welds either by using holes left by the spot weld
cutter, or through holes punched and drilled for
the purpose, approximately 8mm (0.134 ins)
diameter.
8.Dress all welds using either a sander with 36
grit disc, or a belt-type sander and/or wire
brush. When dressing welds ensure an area as
small as possible is removed to protect the zinc
coating.

PANEL REPAIRS
REPAIRS 77-2-45
'B/C' post reinforcement - 3 door
In this procedure, the rear outer body side panel and
the rear quarter front lower reinforcement are
replaced in conjunction with the 'B/C' post
reinforcement.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove rear wheel arch extension.

+ EXTERIOR FITTINGS, REPAIRS,
Wheelarch extension - rear wing part.
6.Remove rear wheel arch liner.
7.Remove front seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Automatic belt assembly - front - 3 door.
8.Remove front door striker from 'B/C' post.
9.Remove rear seat.

+ SEATS, REPAIRS, Rear seat - LH.

+ SEATS, REPAIRS, Rear seat - RH.
10.Remove rear body side casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - body side - rear - 3
door.
11.Remove treadplate from side door aperture.
12.Remove side door aperture seal.
13.Release carpet from inner sill and position
aside.
14.Remove rear quarter vent and seal.

+ EXTERIOR FITTINGS, REPAIRS,
Body quarter vent assembly - 3 door.
15.Remove rear roof panel finisher.
16.Remove headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.
17.Release vehicle harness from inner sill 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.

PANEL REPAIRS
77-2-46 REPAIRS
Refit
1.Secure vehicle harness to inner sill.
2.Fit headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.
3.Fit rear roof panel finisher.
4.Fit seal and rear quarter vent.

+ EXTERIOR FITTINGS, REPAIRS,
Body quarter vent assembly - 3 door.
5.Secure carpet to inner sill.
6.Fit side door aperture seal.
7.Fit treadplate from side door aperture.
8.Fit rear body side casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - body side - rear - 3
door.
9.Fit rear seat.

+ SEATS, REPAIRS, Rear seat - LH.

+ SEATS, REPAIRS, Rear seat - RH.
10.Fit front door striker to 'B/C' post.
11.Fit front seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Automatic belt assembly - front - 3 door.
12.Fit rear wheel arch liner.
13.Fit rear wheel arch extension.

+ EXTERIOR FITTINGS, REPAIRS,
Wheelarch extension - rear wing part.
14.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
15.Connect all ECUs.
16.Connect alternator.
17.Connect battery earth lead.
'B/C' post reinforcement - 5 door
In this procedure, the rear outer body side panel and
the inner panel are replaced in conjunction with the
'B/C' post reinforcement.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove rear door.

+ DOORS, REPAIRS, Door assembly
- rear - remove for access & refit.
5.Remove headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
6.Remove front seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Automatic belt assembly - front - 5 door.
7.Remove 'B/C' post lower finisher.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim finisher - 'B' post - lower - 5
door.
8.Remove front door striker from 'B/C' post.
9.Remove front seat.

+ SEATS, REPAIRS, Front seat.
10.Remove rear seat.

+ SEATS, REPAIRS, Rear seat - LH.

+ SEATS, REPAIRS, Rear seat - RH.
11.Remove treadplate from side door aperture(s).
12.Remove side door aperture seal(s).
13.Release carpet from inner sill and position
aside.
14.Release vehicle harness from inner sill and
position aside.

PANEL REPAIRS
77-2-48 REPAIRS
Refit
1.Secure vehicle harness to inner sill.
2.Position carpet to inner sill.
3.Fit side door aperture seal(s).
4.Fit treadplate from side door aperture(s).
5.Fit rear seat.

+ SEATS, REPAIRS, Rear seat - LH.
6.Fit front seat.

+ SEATS, REPAIRS, Front seat.
7.Fit front door striker to 'B/C' post.
8.Fit 'B/C' post lower finisher.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim finisher - 'B' post - lower - 5
door.
9.Fit front seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Automatic belt assembly - front - 5 door.
10.Fit headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
11.Fit rear door.

+ DOORS, REPAIRS, Door assembly
- rear - remove for access & refit.

+ SEATS, REPAIRS, Rear seat - RH.
12.Connect all ECUs.
13.Connect alternator.
14.Connect battery earth lead.
Complete rear quarter - 3 door
In this procedure, the rear outer body side panel is
replaced in conjunction with the complete rear
quarter.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove sill lower finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Finisher - sill - lower.
6.Remove rear bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
7.Remove rear wheel arch liner.
8.Remove door striker from 'B' post.
9.Remove treadplate from front door aperture.
10.Remove front door aperture seal.
11.Release carpet from inner sill and rear
heelboard and position aside.
12.Remove soft/hard top.
13.Remove tail door aperture seal.
14.Remove rear roof panel finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Moulding - roof - 5 door.
15.Remove tail lamp.

+ LIGHTING, REPAIRS, Lamp
assembly - tail.
16.Remove rear quarter lower casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 3 door.
17.Remove rear quarter upper casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - upper
- 3 door.
18.Remove rear side seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - rear - LH.
19.Remove loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
20.Remove rear seat.

+ SEATS, REPAIRS, Rear seat - LH.

+ SEATS, REPAIRS, Rear seat - RH.
21.Remove rear body side casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - body side - rear - 3
door.
22.Remove headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.

PANEL REPAIRS
77-2-50 REPAIRS
10.Fit rear seat.

+ SEATS, REPAIRS, Rear seat - LH.

+ SEATS, REPAIRS, Rear seat - RH.
11.Fit loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
12.Fit rear side seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - rear - LH.
13.Fit rear quarter upper casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - upper
- 3 door.
14.Fit rear quarter lower casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 3 door.
15.Fit tail lamp.

+ LIGHTING, REPAIRS, Lamp
assembly - tail.
16.Fit rear roof panel finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Moulding - roof - 5 door.
17.Fit tail door aperture seal.
18.Fit soft/hard top.
19.Secure carpet to inner sill and rear heelboard.
20.Fit front door aperture seal.
21.Fit treadplate to front door aperture.
22.Fit door striker to 'B' post.
23.Fit rear wheel arch liner.
24.Fit rear bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
25.Fit sill lower finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Finisher - sill - lower.
26.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
27.Connect all ECUs.
28.Connect alternator.
29.Connect battery earth lead.
Complete rear quarter - 5 door
In this procedure, the rear outer body side panel is
replaced in conjunction with the complete rear
quarter.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove sill lower finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Finisher - sill - lower.
6.Remove rear bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
7.Remove rear wheel arch liner.
8.Remove rear door striker from 'D' post.
9.Remove treadplate from rear door aperture.
10.Remove rear door aperture seal.
11.Release carpet from inner sill and rear
heelboard and position aside.
12.Remove tail door glass upper finisher.
13.Remove tail door glass side finisher.

+ DOORS, REPAIRS, Finisher - rear
screen - side - 5 door.
14.Remove tail door aperture seal.
15.Remove roof panel finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Moulding - roof - 5 door.
16.Remove tail lamp.

+ LIGHTING, REPAIRS, Lamp
assembly - tail.
17.Remove rear quarter lower casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
18.Remove rear quarter upper casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - upper
- 5 door.
19.Remove rear side seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - rear - LH.
20.Remove loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
21.Remove rear seat.

+ SEATS, REPAIRS, Rear seat - LH.

+ SEATS, REPAIRS, Rear seat - RH.
22.Remove headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.

PANEL REPAIRS
77-2-52 REPAIRS
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.
2.Arrow A is shown to highlight the fact that there
are plug welds on the other side of the inner
wheel arch as well. These are to weld the rear
longitudinal to the inner wheel arch.
Refit
1. LH side: Fit tail door striker to 'E' post.
2. RH side: Fit fuel tank.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Tank - Non NAS.
3. RH side: Fit fuel filler neck.

+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Filler neck.
4. RH side: Fit tail door.

+ DOORS, REPAIRS, Door - tail
assembly - remove for access & refit.
5.Secure vehicle harness to rear quarter.
6.Fit rear damper.

+ REAR SUSPENSION, REPAIRS,
Damper.
7.Fit rear body side glass.

+ SCREENS, REPAIRS, Glass - body
side - rear.
8.Fit headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.9.Fit rear seat.

+ SEATS, REPAIRS, Rear seat - LH.

+ SEATS, REPAIRS, Rear seat - RH.
10.Fit loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
11.Fit rear side seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - rear - LH.
12.Fit rear quarter upper casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - upper
- 5 door.
13.Fit rear quarter lower casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
14.Fit tail lamp.

+ LIGHTING, REPAIRS, Lamp
assembly - tail.
15.Fit roof panel finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Moulding - roof - 5 door.
16.Fit tail door aperture seal.
17.Fit tail door glass side finisher.

+ DOORS, REPAIRS, Finisher - rear
screen - side - 5 door.
18.Fit tail door glass upper finisher.
19.Secure carpet to inner sill and rear heelboard.
20.Fit rear door aperture seal.
21.Fit treadplate to rear door aperture.
22.Fit rear door striker to 'D' post.
23.Fit rear wheel arch liner.
24.Fit rear bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper valance - rear - up to 04MY.
25.Fit sill lower finisher.

+ EXTERIOR FITTINGS, REPAIRS,
Finisher - sill - lower.
26.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
27.Connect all ECUs.
28.Connect alternator.
29.Connect battery earth lead.

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.