LAND ROVER FREELANDER 2001 Workshop Manual

CORROSION PREVENTION AND SEALING
77-4-30 INTERNAL SEALING
Sound dampening foam injection points - 5 door
Cavities symmetrically opposite to those shown must also be treated.
1'A' post reinforcement to sill reinforcement/inner sill
2'B/C' post reinforcement to sill reinforcement/inner sill
3Outer wheelarch to outer body side

CORROSION PREVENTION AND SEALING
LEAK DETECTION 77-4-31
LEAK DETECT ION
Water Leaks
Where water leakage is involved, always adopt a logical approach to the problem using a combination of skill,
experience and intuition. Do not reach a conclusion based only on visual evidence, such as assuming that a wet
footwell is caused by a leak emanating from the windscreen. It will often be found that the source of the leak is
elsewhere. Use of the correct procedure will increase the chance of locating a leak, however obscure it may seem.
Tools and equipment
The following tools and equipment are recommended for the purpose of detection and rectification of water leaks:
1Garden sprayer (hand-operated).
2Wet/dry vacuum cleaner.
3Dry, absorbent cloths.
4Battery torch.
5Small mirror.
6Weatherstrip locating tool.
7Trim panel remover.
8Small wooden or plastic wedges.
9Dry compressed air supply.
10Hot air blower.
11Sealer applicators.
12Ultrasonic leak detector.
During leak detection, the vehicle should be considered in three basic sections:
lThe front interior space.
lThe rear passenger space.
lThe loadspace or boot.
Testing
From the information supplied by the customer it should be possible for the bodyshop operator to locate the starting
point from which the leak may be detected. After the area of the leak has been identified, find the actual point of entry
into the vehicle.
A simple and effective means in the first instance is an ordinary garden spray with provision for pressure and jet
adjustment, which will allow water to be directed in a jet or turned into a fine spray. Use a mirror and a battery-powered
torch (NOT a mains voltage inspection lamp) to see into dark corners.
The sequence of testing is particularly important. Start at the lowest point and work slowly upwards, to avoid testing
in one area while masking the leak in another. For example, if testing started at the level of the windscreen, any water
cascading into the plenum chamber could leak through a bulkhead grommet and into the footwells. Even at this point
it could still be wrongly assumed that the windscreen seal was at fault.
Another important part of identifying a water leak is by visual examination of door aperture seals, grommets and
weatherstrips for damage, deterioration or misalignment, together with the fit of the door itself against the seals.
Sealing
When the point of the leak has been detected, it will then be necessary to rectify it using the following procedure:
1Renew all door aperture seals and weatherstrips which have suffered damage, misalignment or deterioration.
2Check all body seals to ensure that they are correctly located on their mounting flanges/faces using a lipping
tool if necessary.
3Dry out body seams to be treated using compressed air and/or a hot air blower as necessary.
4Apply sealant on the outside of the joint wherever possible to ensure the exclusion of water.
5When rectifying leaks between a screen glass and its weatherstrip (or in the case of direct glazing, between the
glass and bodywork), avoid removing the glass if possible. Apply the approved material at the appropriate
location (i.e. glass to weatherstrip or glass to body).

PAINTING
PANEL PROCEDURES 77-5-1
PAINTING PANEL PROCEDURES
Panel Preparation
General
Replacement panels are supplied with a cathodic primer coating as part of the panel protection and in compliance
with the vehicle's Corrosion Warranty, where applicable. DO NOT remove the primer before paint refinishing. In
the event of localized surface damage or imperfections, ensure that only the minimum of primer is removed
during rectification work for effective repair.
Rectify damage as far as possible by panel beating or straightening. To remove corrosion or paint runs on outer
surfaces, abrade the primer coat in the affected area as necessary using the following procedure:
1Clean the panel using a solvent wipe.
2Treat exposed areas of metal with an etch phosphate process.
3Re-treat the affected area using either a separate acid-etch primer and two-pack surfacer, or an integrated etch
primer/filler.
Panel Preparation
The following procedures should be applied when repairing panels.
Welded panels
1Remove primer from the immediate vicinity of new and existing panel flanges, cleaning to bright metal finish.
2On joints to be spot welded, apply weld-through zinc rich primer to joint faces of both flanges. Make spot welds
while primer is still wet or according to the manufacturer's instructions.
3Dress accessible weld joints.
4Clean panel using solvent wipe.
5Treat bare metal with an etch phosphate process.
6Re-treat repaired areas.
Sectioned panels
When replacing part or sectioned panels, the basic procedure is the same as for welded panels described above, with
the following variations:
1Remove primer from both new and existing joint faces, cleaning to a bright metal finish.
2Where an overlap joint with the existing panel is to be spot welded, apply weld-through, zinc rich primer to both
joint faces and spot weld while the primer is still wet, or according to the manufacturer's instructions.
3MIG weld butt joints where applicable.
4Clean the panel with a solvent wipe.
5Treat bare metal areas using an etch phosphate process.
6Re-prime affected areas as necessary as for rectifying transit damage.
7Treat the inner faces of lap or butt joints with a suitable cavity wax.
Clinched panels
1Abrade primer on new and existing panel joint faces, and clean using a solvent wipe.
2Apply metal-to-metal adhesive where applicable.
3Where joints are to be spot welded, apply suitable weld-through, zinc rich primer to weld areas.
4Where joints are to be MIG, arc or gas welded, apply zinc rich primer in adjacent areas but leave the welded
area untreated.
5To retain the panel while clinching the flanges, tack spot weld or plug weld as appropriate.
6Clean the panel with a solvent wipe.
7Treat bare metal areas with a suitable etch phosphate process.
8Re-prime affected areas as necessary as for rectifying transit damage.
PAINT P ROCEDURES

PAINTING
77-5-2 PAINT PROCEDURES
Paint preparation
Paint refinishing
The following process must be adhered to for paint refinishing operations.
1Seal required exterior and interior seams with an approved seam sealer

+ , , .
2Repair any damage to underbody sealers

+ , , Corrosion Prevention.
3Apply a two-pack paint refinishing system
4Apply cavity wax to all interior surfaces which have not received refinish paint
Paint repairs
Before carrying out paintwork repairs, clean the vehicle thoroughly using either a steam cleaner or high-pressure
washer.
Wash locally repaired areas using a mild water-mixable detergent and wipe them clean with solvent, immediately
before paint application.
Ensure that damaged paintwork which has led to exposed metal is abraded until the metal is clean, extending beyond
the area of the original damage. Treat the bare metal with an etch phosphate to remove all traces of rust and to provide
a key for new paint coats. Re-treat the affected area using either a separate acid-etch primer and two-pack surfacer
or an integrated etch primer/filler, and follow with a two-pack paint system. Treat those surfaces not receiving paint
using an approved cavity wax, following paint operations.
aTwo-pack top coat
bTwo-pack primer filler and etch primer
cEtch phosphate
When heat curing paint repairs, the temperature must not exceed 65°C (149°F). Temperatures above this
figure will cause the reflective elements within the headlamps and tail lamps to distort and may damage other
components.

HEATING AND VENTILATION
REPAIRS 80-1
HEATING A ND VENT ILATION REPAIRS
Controls - heater - up to 04MY
$% 80.10.02
Remove
1.Remove front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
2.Release air blend control cable from control
knob and abutment.
3.Release air distribution control cable from
control knob and abutment.
4.Disconnect multiplugs from all switches.
5.Disconnect illumination multiplug.
6.Remove heater controls.
7.Remove fan speed switch drive shaft.8.Remove 2 screws securing fan speed switch
and remove switch.
9.Remove 5 switches from heater controls.
Refit
1.Fit switches to heater control housing.
2.Fit fan speed switch and secure with screws.
3.Fit drive shaft to fan speed switch.
4.Fit heater control assembly to vehicle.
5.Connect switch and illumination multiplugs.
6.Connect air blend control cable to control knob
and abutment.
7.Connect air distribution control cable to control
knob and abutment.
8.Fit front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.

HEATING AND VENTILATION
80-2REPAIRS
Controls - heater - from 04MY
$% 80.10.02
Remove
1.Remove the Radio/CD module.

+ IN CAR ENTERTAINMENT,
REPAIRS, Radio/CD - from 04MY.
2.Remove 4 screws securing heater controls to
fascia.
3.Move heater control assembly to access
cables.
4.Release air distribution cables from control
knobs and abutments.
5.Disconnect 3 multiplugs from heater control
assembly.
6.Remove heater controls.Refit
1.Fit heater control assembly to vehicle.
2.Connect multiplugs.
3.Connect heater control cables and secure to
abutment with clips.
4.Position heater control panel, fit and tighten
screws.
5.Fit Radio/CD module.
+ IN CAR ENTERTAINMENT,
REPAIRS, Radio/CD - from 04MY.
M80 0578

HEATING AND VENTILATION
REPAIRS 80-3
Servo - air recirculation
$% 80.10.18
Remove
1.Remove glove box.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Glove box.
2.Disconnect multiplug from servo.
3.Remove screw securing servo to evaporator
and remove servo.
Refit
1.Fit servo to evaporator and secure with screw.
2.Connect multiplug to servo.
3.Fit glove box.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Glove box.
Switch - recirculation control
$% 80.10.21
Remove
1.Remove 3 heater control knobs.
2.Remove 2 screws securing heater control
finisher to heater controls and remove finisher.
3.Release switch and disconnect multiplug.
4.Remove switch.
Refit
1.Fit recirculation switch to heater control panel
and connect multiplug.
2.Fit heater control finisher to heater controls and
secure with screws.
3.Fit heater control knobs.

HEATING AND VENTILATION
80-4REPAIRS
Switch - fan - front heater
$% 80.10.22
Remove
1.Remove front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
2.Disconnect multiplug from switch.
3.Remove drive shaft from switch.4.Remove 2 screws securing switch to heater
controls.
5.Remove switch.
Refit
1.Fit switch to heater controls and secure with
screws.
2.Fit drive shaft to switch.
3.Connect multiplug to switch.
4.Fit front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.

HEATING AND VENTILATION
REPAIRS 80-5
Ventilator - face level - LH
$% 80.15.05
Remove
1.Protect fascia and carefully lever vent from
fascia.
2.Remove and discard seal.Refit
1.Fit new seal to vent.
2.Fit vent to fascia.