2001 LAND ROVER FREELANDER engine

PANEL REPAIRS
REPAIRS 77-2-41
Refit
1. Driver's side: Fit passenger compartment fuse
box.
2.Fit insulation pads to engine bulkhead.
3.Fit front door aperture seal.
4.Position front carpet and fit treadplate to front
door aperture.
5.Fit windscreen.

+ SCREENS, REPAIRS, Windscreen.
6.Fit headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.
7.Fit duct of outboard face level ventilator.
8.Fit fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
9.Fit front seat.

+ SEATS, REPAIRS, Front seat.
10.Fit front door.

+ DOORS, REPAIRS, Door assembly
- front - remove for access & refit.
11.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
12.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
13.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
14.Connect all ECUs.
15.Connect alternator.
16.Connect battery earth lead.
'A' post - 5 door
In this procedure, the front outer body side panel is
replaced in conjunction with the inner 'A' post and the
'A' post reinforcements.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
6.Remove front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
7.Remove front door.

+ DOORS, REPAIRS, Door assembly
- front - remove for access & refit.
8.Remove front seat.

+ SEATS, REPAIRS, Front seat.
9.Remove fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
10.Remove duct of outboard face level ventilator.
11.Remove headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
12.Remove windscreen.

+ SCREENS, REPAIRS, Windscreen.
13.Remove treadplate from front door aperture.
Release front carpet and position aside.
14.Remove front door aperture seal.
15.Remove engine bulkhead insulation.
16. Driver's side: Remove passenger
compartment fuse box.

PANEL REPAIRS
77-2-42 REPAIRS
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.
Refit
1. Driver's side: Fit passenger compartment fuse
box.
2.Fit insulation pads to engine bulkhead.
3.Fit front door aperture seal.
4.Position front carpet and fit treadplate to front
door aperture.
5.Fit headlining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
6.Fit windscreen.

+ SCREENS, REPAIRS, Windscreen.
7.Fit duct of outboard face level ventilator.
8.Fit fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
9.Fit front seat.

+ SEATS, REPAIRS, Front seat.
10.Fit front door.

+ DOORS, REPAIRS, Door assembly
- front - remove for access & refit.
11.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
12.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
13.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
14.Connect all ECUs.
15.Connect alternator.
16.Connect battery earth lead.

BODY SEALING MATERIALS
APPROVED MATERIALS 77-3-3
APPROVED MATERIALS
Description - Usage Supplier Part Number
Cavity waxes
Inner Cavity Wax (Amber) 3M 08901/11/21
Inner Cavity Wax (Transparent) 3M 08909/19/29
Cavity Wax Croda PW57
Engine bay waxes/lacquers
Astrolan Engine Bay Wax and Cosmetic Wax Astors DA3243/1
Engine Bay and Cosmetic Wax/Lacquer Croda PW197
Engine Bay Cosmetic Wax/Lacquer Dinol 4010
Miscellaneous materials
Aerosol Auto Adhesive (Trim) - impact adhesive for trim parts 3M 08080
Flexible Parts Repair Material - rubber modified polypropylene parts 3M 05900
Sound Dampening Foam Gurit-Essex Betacore 7999
Sound Dampening Pillar Foam Duramix 4330
Flexible Foam (anti-flutter) - used between panels, allows for a degree of
movementDuramix 4320
Water Shedder Repair (Aerosol) Teroson -
Seam sealers
Body Caulking - type (b) gaps between panels 3M 08568
Drip Chek Clear - bolted, spot welded and bonded panel edges; type(a) and (b)
gaps between panels; type (c) clinch joints3M 08401
Drip Chek Heavy - type (b) gaps between panels; type (c) clinch joints 3M 08531
Description - Usage Supplier Part Number
Seam sealers (continued)
Polyurethane Seam Sealer - bolted, spot welded and bonded panel edges; type
(a) and (b) gaps between panels; type (b) clinch joints3M 08684/89/94
Polyurethane Sealer (Sachet) - bolted panel edges; type (b) clinch joints 3M 08703/83/88
Sprayable Sealer - lap joints 3M 08800/23
Super Seam Sealer - lap joints; type (b) clinch joints 3M 08537
Weld Thru' Sealer - between spot welded panels 3M 08626
Betafill Clinch and Brushable Sealer - type (b) clinch joints Gurit-Essex 10211/15/20
Clinch, Joint and Underbody Coating - lap joints Gurit-Essex 10101/10707
Leak Chek Clear - between bolted panels; spot welded and bonded panel edges;
type (c) clinch joints; type (a) gaps between panelsKent Industries 10075
Putty - type (b) gaps between panels Kent Industries -
Polyurethane Seam Sealer - bolted, spot welded and bonded panel edges;
between bonded panels; type (a) and (b) gaps between panelsPPG 6500
Polyurethane Seam Sealer - bolted, spot welded and bonded panel edges;
between bonded panels; type (b) gaps between panelsTeroson 92
Terolan Light Seam Sealer - bolted, spot welded and bonded panel edges; type
(a) and (b) gaps between panels; between bonded panels; type (c) clinch jointsTeroson -
Terolan Special Brushable Seam Sealer - lap joints Teroson -
Terostat Sprayable Seam Sealer - bolted, spot welded and bonded panel edges;
between bonded panels; type (b) gaps between panelsTeroson 9320
Terostat 1K PU Seam Sealer (SE 20) - type (a) and (b) gaps between panels;
spot welded and bonded panel edgesTeroson -
Sealing Compound - bolted, spot welded and bonded panel edges; between
bonded panels; type (b) gaps between panelsWurths 8901001/-/6

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
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.

CORROSION PREVENTION AND SEALING
77-4-24 SEALING
Sealed seams in front wheelarch, engine compartment and screen rail
Seams symmetrically opposite to those shown are also treated. Use putty on seams marked 'A'. On windscreen rail,
sealant to be finished flush to adjacent surfaces over length 'B'. On front suspension turrets, ensure damper mounting
holes are kept free of sealant.

HEATING AND VENTILATION
REPAIRS 80-11
Harness - positive temperature co-
efficient (PTC) heater - Td4 models
$% 80.20.06
Remove
1.Disconnect battery earth lead.
2.Remove bolt securing PTC cable from positive
side of battery.
3.Remove ECM from 'E' box.

+ ENGINE MANAGEMENT SYSTEM -
EDC, REPAIRS, Engine control module
(ECM).
4.Disconnect multiplugs from gearbox ECU and
cooling fan sensor5.Release harness from cable ties and release
relays from inner casing.
6.Release and disconnect cooling fan and joint
harness multiplugs.
7.Release 3 harnesses and air duct rubber
sleeve's from housing.
8.Release clips and remove fuse box cover.
9.Remove nut securing ECM housing.
10.Release housing from retaining brackets and
remove.
M80 0557