LAND ROVER FREELANDER 2001 Workshop Manual

PANEL REPAIRS
77-2-66 TIMES
5 door - Rear end combination panel times
Panel/assembly replacement times 3 Door
Panel description Total time
Rear bumper
Rear outer bodyside panel
E-post inner assembly
Gusset rear floor
Crossmember assembly rear floor
31.2 LH
33.4 RH
Rear bumper
Rear outer bodyside panel LH & RH
E-post inner assembly LH & RH
Gusset rear floor LH & RH
Crossmember assembly rear floor
51.2
Rear bumper
Rear outer bodyside panel
E-post inner assembly
Quarter complete rear assembly
Gusset rear floor
Crossmember assembly rear floor
Longitudinal rear section
Rear floor panel
44.7 LH
46.8 RH
Rear bumper
Rear outer bodyside panel LH & RH
E-post inner assembly LH & RH
Quarter complete rear assembly LH & RH
Gusset rear floor LH & RH
Crossmember assembly rear floor
Longitudinal rear section LH & RH
Rear floor panel
69.2
Panel Description Total time
Body side LH 30.1
Body side RH 31.9
Door front - each 8.9
Door rear - each 8.1
Door skin front - each 12.9
Front bulkhead assembly 12.6
Crossmember assembly rear floor 12.1
Roof assembly 19.9
Bodyside lower outer LH 14
Bodyside lower outer RH 14.1
Bodyside rear outer LH 22.4
Bodyside rear outer RH 24.3

PANEL REPAIRS
TIMES 77-2-67
Combination panel replacement times (3 door)
The following panel combination times show the total time to remove/refit body panels, MET items and any paint
processes. Times for 3 door front end combination panel replacement will be the same as 5 door.
3 Door - Bodyside combination panel times
Panel description Total time
Front door
Wing
12.2
Front door
Rear outer bodyside panel
27.2 LH
29.7 RH
Front door
Bodyside assembly
34.6 LH
36.4 RH
Front door
Bodyside assembly
Wing
37.7 LH
40.2 RH
Front door
Front outer bodyside panel
A-post reinforcement
Windscreen
Wing
Valance outer reinforcement rear section
33.8 LH
35.1 RH

PANEL REPAIRS
77-2-68 TIMES
3 Door - Rear end combination panel times
Panel description Total time
Rear bumper
Rear outer bodyside panel
E-post inner assembly
Gusset rear floor
Crossmember assembly rear floor
34.4LH
36.7 RH
Rear bumper
Rear outer bodyside panel LH & RH
E-post inner assembly LH & RH
Gusset rear floor LH & RH
Crossmember assembly rear floor
54.8
Rear bumper
Rear outer bodyside panel
E-post inner assembly
Quarter complete rear assembly
Gusset rear floor
Crossmember assembly rear floor
Longitudinal rear section
Rear floor panel
49 LH
50.6 RH
Rear bumper
Rear outer bodyside panel LH & RH
E-post inner assembly LH & RH
Quarter complete rear assembly LH & RH
Gusset rear floor LH & RH
Crossmember assembly rear floor
Longitudinal rear section LH & RH
Rear floor panel
75.3

BODY SEALING MATERIALS
MATERIALS AND APPLICATIONS 77-3-1
BODY SEALING MAT ERIALS
1Between panels - bolted
2Panel edges - bolted
3Between panels - spot welded
4Panel edges - spot welded
5Between panels - bonded
6Panel edges - bonded
7Clinch joints - type (a)
8Clinch joints - type (b)
9Clinch joints - type (c)
10Gaps between panels - type (a)
11Gaps between panels - type (b)
12Lap joint

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

BODY SEALING MATERIALS
77-3-4 APPROVED MATERIALS
Description - Usage Supplier Part Number
Structural adhesives
Automotive Structural Adhesive - between bonded panels; type (a) clinch joints 3M 08122
Two Part Structural Epoxy - between bonded and spot welded panels; type (a)
clinch jointsCiba-Geigy XB5106/7
Underbody sealers
Body Schutz 3M 08861
Spray Schutz 3M 08877
Crodapol Brushable Underbody Sealer Croda PV75
Terotex Underseal (CP 02) Teroson 9320
Underbody waxes
Stone-chip coating (smooth) 3M 08158/9
Underbody Wax Croda PW61
Underbody Wax Dinol Tectacote 205
Weld-through primers
Weld Thru' Coating 3M 05913
Zinc Spray 3M 09113
Zinc Rich Primer ICI P-565 634

BODY SEALING MATERIALS
APPLICATION EQUIPMENT 77-3-5
APPLICATION EQUIPMENT
Application Equipment
Suitable application equipment is available from the following manufacturers and suppliers:
3M
Automotive Trades Group
3M UK Plc
3M House
PO Box 1
Market Place
Bracknell
Berks.
RG12 1JU
( (01344) 858611
Cooper Pegler
Burgess Hill
Sussex
RH15 9LA
( (014 446) 42526
SATA Spray Equipment
Minden Industrial Ltd.
16 Greyfriars Road
Moreton Hall
Bury St. Edmunds
Suffolk
IP32 7DX
( (01284) 760791
3M Body Schutz Pistol Spraygun 08996
A pistol type spraygun constructed from case and machined light alloy and designed for use with 3M screw fit Body
Schutz containers.
3M Pneumatic Cartridge Gun 08012
Air line-fed gun for applying 3M cartridge products. Excellent for ease of application to obtain a smooth bead.
Regulator valve for additional control.
3M Pneumatic Applicator Guns 08006/7
Air line-fed gun for application of 3M sachet sealers (Part Number 08006 for 200ml and 310ml sachet applications,
and Part Number 08007 for all size sachets including 600ml).
Also available: Heavy Duty Manual Gun 08013.
3M Applicator Gun 08190.
For the application of 3M Structural Adhesive 08120.
3M Inner Cavity Wax Applicator Gun 08997
This equipment accepts 1-litre canisters and has a 750mm flexible tube.
The approved system is available from all 3M refinishing factors.

BODY SEALING MATERIALS
77-3-6 APPLICATION EQUIPMENT
Cooper Pegler Falcon Junior Pneumatic Gun (Airless)
Intended primarily for applying transit wax, this pneumatic sprayer has a 5-litre container with integral hand pump and
provides an effective means of wax spraying without the need for compressed air or additional services.
A selection of nozzles, lances, hose lengths and a trigger valve assembly with integral filter allows flexibility in use.
Additional applications include general maintenance, wax injection and paint application. Heavy-bodied materials
may also be applied. All parts are fully replaceable and a wide range of nozzle configurations is available.
SATA Schutz Gun Model UBE
The SATA Schutz Gun is approved for the retreatment of vehicle underbody areas with protective coatings as
supplied in 1 litre, purpose-designed 'one-way' containers. The screw thread fitting (female on the gun) is standard
to most Schutz-type packs.
Full operating details are supplied with the equipment.
SATA HKD1 Wax Injection Injection Equipment
This equipment is approved for carrying out cavity wax re-treatment. The SATA HKD1 set comprises a high quality
forged gun with 1-litre pressure feed container, a flexible nylon lance, a straight 1100mm steel lance and hooked-
wand lance. A quick-change coupling is provided as a standard fitting to allow lances to be easily interchanged. Each
lance has an integral, machined nozzle with specialised spray characteristics to suit the type of box section to be
treated.

BODY SEALING MATERIALS
APPLICATION EQUIPMENT 77-3-7
Cavity wax application equipment and techniques
1Air inlet
2Flow control (spray pattern adjustment)
3Pressure cup (1 litre capacity). Maximum
pressure 140PSI (9.7 bar, 9.84kg/cm3)
4Gun connector
5Lance nipple connection
6Flexible lance
7Rigid directional hook wand (forward cone
spray pattern)
8Flexible nylon lance (1100mm) with 360° spray
pattern
9 Rigid lance (1100mm) with 360° spray pattern
When re-treating wax-injected areas which have been disturbed during repairs, it is necessary to use a compressed
air spray gun with integral pressure cup and a selection of interchangeable lances.
The following points must be observed during use, according to the attachments fitted:
lUse the rigid or flexible lance attachments with 360° spray dispersal when treating enclosed areas, to ensure
maximum coverage.
lWhere openings are restricted, use the hook nozzle to provide a more directional spray (e.g. inside narrow or
short box sections).
lSpray exposed underbody surfaces directly from the gun less lance attachment and without disconnecting the
fluid coupling.