Page 840 of 1007

CORROSION PREVENTION AND SEALING
SEALING 77-4-9
Inspections during maintenance servicing
It is a requirement of the Corrosion Warranty that the vehicle body is checked for corrosion by an authorised Land
Rover Dealer at least once a year, to ensure that the factory-applied protection remains effective.
Service Job Sheets include the following operations to check bodywork for corrosion:
lWith the vehicle on a lift, carry out visual check of underbody sealer for damage.
lWith the vehicle lowered, inspect exterior paintwork for damage and body panels for corrosion.
The vehicle must be washed and free from deposits prior to inspection. It is part of the owner's responsibility to ensure
that the vehicle is kept free of accumulations of mud which could accelerate the onset of corrosion. It will be necessary
for the vehicle to be washed by the Dealer prior to inspection of bodywork if the customer has offered the vehicle in
a dirty condition. Particular attention should be paid to areas where access is difficult.
The checks described above are intended to be visual only. It is not intended that the operator should remove trim
panels, finishers, rubbing strips or sound-deadening materials when checking the vehicle for corrosion and paint
damage.
With the vehicle on a lift, and using an inspection or spot lamp, visually check for the following:
lCorrosion damage and damaged paintwork, condition of underbody sealer on front and rear lower panels, sills
and wheel arches.
lDamage to underbody sealer. Corrosion in areas adjacent to suspension mountings and fuel tank fixings.
The presence of small blisters in underbody sealer is acceptable, providing they do not expose bare metal.
Pay special attention to signs of damage caused to panels or corrosion protection material by incorrect jack
positioning.
caut : It is essential to follow the correct jacking and lifting procedures.
With the vehicle lowered, visually check for evidence of damage and corrosion on all visible painted areas, in
particular the following:
lFront edge of bonnet.
lVisible flanges in engine compartment.
lLower body and door panels.
Rectify any bodywork damage or evidence of corrosion found during inspection as soon as is practicable, both to
minimise the extent of the damage and to ensure the long term effectiveness of the factory-applied corrosion
prevention treatment. Where the cost of rectification work is the owner's responsibility, the Dealer must advise the
owner and endorse the relevant documentation accordingly.
Where corrosion has become evident and is emanating from beneath a removable component (e.g. trim panel,
window glass, seat etc.), remove the component as required to permit effective rectification.
Page 846 of 1007
CORROSION PREVENTION AND SEALING
SEALING 77-4-15
Adhesive on body side and roof - 3 door
Joints symmetrically opposite to those shown are also treated. Apply 3 mm diameter beads except where detailed
otherwise (below).
1Apply 4 x 10 mm diameter spots
2Apply 3 x 4 mm diameter beads
3Apply 3 x 10 mm diameter spots
4Apply 6 mm diameter bead (fuel resistant seam sealer)
Page 847 of 1007
CORROSION PREVENTION AND SEALING
77-4-16 SEALING
Adhesive on body side - 5 door
Joints symmetrically opposite to those shown are also treated. Apply 3 mm diameter beads except where detailed
otherwise (below).
1Apply 4 x 10 mm diameter spots
2Apply 3 x 4 mm diameter beads
3Apply 3 x 10 mm diameter spots
4Apply 4 x 10 mm diameter spots
5Apply 3 x 4 mm diameter beads
6Apply 3 x 10 mm diameter spots
7Apply 6 mm diameter bead (fuel resistant seam sealer)
Page 853 of 1007
CORROSION PREVENTION AND SEALING
77-4-22 SEALING
Seam sealer on fuel filler and roof - 3 door
Seams symmetrically opposite to those shown are also treated. On roof seams, sealant to be finished flush to surface
forward of points 'A' and rearward of points 'B'.
Page 854 of 1007
CORROSION PREVENTION AND SEALING
SEALING 77-4-23
Seam sealer on fuel filler and roof - 5 door
Seams symmetrically opposite to those shown are also treated. On roof seam, sealant to be finished flush to surface
forward of point 'A'.
Page 883 of 1007

HEATING AND VENTILATION
80-18REPAIRS
Fuel burning heater (FBH)
$% 80.40.01
Remove
1.Disconnect battery earth lead.
2.Remove front bumper.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
3.Drain coolant.
+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.
4.Position container to collect coolant spillage.
5.Release clips, disconnect coolant feed and
return hoses from FBH.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
6.Position an absorbent cloth, release clip and
remove fuel feed hose from FBH. Plug
connections and move aside.7.Loosen 1 bolt and remove other bolt securing
FBH mounting bracket to body.
8.Release FBH from mounting, disconnect
multiplugs and move assembly aside.
NOTE: Do not carry out further dismantling if
component is removed for access only.
9.Remove 3 bolts securing FBH to mounting
bracket.
10.Remove bracket.
M80 0496
M80 0499
Page 884 of 1007

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.
Page 885 of 1007
HEATING AND VENTILATION
80-20REPAIRS
Fuel pump - fuel burning heater - up to
03MY
$% 80.40.40
Remove
1.Disconnect battery earth lead.
2.Remove RH rear wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
3.Disconnect multiplug from fuel pump.
4.Release clips and remove fuel pipes from fuel
pump.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
5.Release fuel pump from rubber mountings and
remove pump.Refit
1.Clean fuel hose connections.
2.Position fuel pump and secure in rubber
mountings.
3.Position fuel pipes to pump and secure with
clips.
4.Connect multiplug to fuel pump.
5.Fit rear wheel arch liner.
+ EXTERIOR FITTINGS, REPAIRS,
Liner - rear wheel arch.
6.Connect battery earth lead.
M80 0495