2001 LAND ROVER FREELANDER exhaust

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.

HEATING AND VENTILATION
REPAIRS 80-19
11.Release clip securing air intake hose to FBH,
release clamp from exhaust manifold.
12.Remove 2 bolts securing air intake and exhaust
assembly to FBH and move aside.
Refit
1.Fit exhaust pipe, air intake hose and bracket
assembly to FBH.
2.Fit and tighten bolts to 10 Nm (7.5 lbf.ft).
3.Tighten exhaust pipe clamp to 5 Nm (3.5 lbf.ft).
4.Align air intake hose with mark on casing and
secure with clip.
5.Fit mounting bracket to FBH and tighten bolts to
10 Nm (7.5 lbf.ft).
6.Connect multiplugs to FBH.
7.Fit FBH to body, tighten bolts to 10 Nm (7.5
lbf.ft).
8.Fit coolant hoses to FBH and secure with clips.
9.Fit fuel feed hose to FBH and secure with clip.
10.Refill cooling system.

+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.
11.Fit front bumper.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
12.Connect battery earth lead.
Sensor - outside temperature (OT)
$% 80.40.31
Remove
1.Remove front bumper.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
2.Disconnect multiplug from OT sensor.
3.Remove OT sensor from mounting bracket,
collect rubber washer and spacer.
Refit
1.Clean OT mounting bracket and sensor.
2.Fit OT sensor to mounting bracket, fit rubber
washer and spacer, connect multiplug.
3.Fit front bumper.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.

CHARGING AND STARTING
86-1-6 REPAIRS
Alternator - K1.8
$% 86.10.02
Remove
1.Disconnect battery earth lead.
2.Remove exhaust manifold heat shield.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES 1.8, REPAIRS, Heat shield -
exhaust manifold - with A/C.
3.Remove bolt securing alternator mounting
bracket. Rotate bracket clear of alternator and
remove bracket.
4.Release cover from battery lead on alternator.
5.Loosen nut securing battery lead to alternator
and release lead.
6.Disconnect multiplug from alternator.
7.Remove nut and bolt from alternator lower
mounting bracket.
8.Remove alternator from mounting bracket.Refit
1.Position alternator to mounting bracket.
2.Fit lower nut and bolt securing alternator but do
not tighten at this stage.
3.Connect multiplug and position battery cable to
alternator and tighten nut.
4.Position battery lead cover.
5.Fit alternator mounting bracket, tighten bolts to
25 Nm (18 lbf.ft).
6.Fit exhaust manifold heat shield.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES 1.8, REPAIRS, Heat shield -
exhaust manifold - with A/C.
7.Connect battery earth lead.
M86 5388