2006 LAND ROVER FRELANDER 2 Repair Manual

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Page 2545 of 3229

LAND ROVER FRELANDER 2 2006 Repair Manual 5. Plug wel d to the front s ide member cl osi ng panel .
6. Dres s all welded joint s.
7. The ins tall ati on of ass ociated panels and mechanicalcomponent s is t he reverse of removal.

Page 2546 of 3229

LAND ROVER FRELANDER 2 2006 Repair Manual Publis hed: 11-May-2011
Front End Sheet Metal Repairs - Front Side Member and Suspension Top Mount
AssemblyRemoval and Ins tallat ion
Removal
• NO TE: The front s ide member and suspens ion t op mo

Publis hed: 11-May-2011
Front End Sheet Metal Repairs - Front Side Member and Suspension Top Mount
AssemblyRemoval and Ins tallat ion
Removal
• NO TE: The front s ide member and suspens ion t op mount as sembly is an ass embly of the front s ide member closing panel, fenderapron panel reinforcement, fender apron panel front ext ens ion, fender apron lower panel, front s ide member and fender apronpanel and the s uspens ion t op mount .
• NO TE: The service panel is not fully welded.
• NO TE: The panel is serviced les s it s weld s tuds
1. The front side member and suspens ion t op mount as sembly isreplaced in conjunct ion wit h:
Front bumper cover
Front bumper armat ure
Hood lat ch panel
Both front fenders
Front bumper mount ing
Fender apron upper panel
Front side member
2. For addit ional information relating t o t his repair procedure pleas es ee t he following:For addit ional informat ion, refer to: Body and Frame (501-26 BodyRepairs - Vehicle Specific Informat ion and Tolerance Checks ,Des cript ion and O perat ion) /Standard W orkshop Pract ices (100-00 General Informat ion,Des cript ion and O perat ion).
3. Remove t he front s ide member.For addit ional informat ion, refer to: Front Side Member (501-27Front End Sheet Met al Repairs, Removal and Ins t allat ion).
4. Remove t he fender apron upper panel.For addit ional informat ion, refer to: Fender Apron Upper Panel(501-27 Front End Sheet Met al Repairs, Removal and Ins t allat ion).
5. Remove t he ins t rument panel.For addit ional informat ion, refer to: Inst rument Panel - TD4 2.2LDiesel (501-12 Inst rument Panel and Cons ole, Removal andIns t allat ion).
6. Remove t he rocker panel inner t rim.
7. Remove t he B-pillar lower t rim.For addit ional informat ion, refer to: B-Pillar Lower Trim Panel(501-05 Int erior Trim and Ornamentat ion, Removal andIns t allat ion).
8. Releas e and lay as ide t he front carpet sect ion.
9. Releas e and lay as ide t he ins ulat ing mat erial at t he out erbulkhead.
10. LH Side: Remove the hood releas e handle.
11. RH Side: Remove the brake boost er.For addit ional informat ion, refer to: Brake Boost er (206-07 PowerBrake Act uat ion, Removal and Ins t allat ion).
12. RH Side: Remove the pedal box.
13. Release and lay aside t he wiring harnes ses at t he a-pillar,bulkhead and s ide member.
14. Mill out t he spot welds .

Page 2547 of 3229

LAND ROVER FRELANDER 2 2006 Repair Manual 15. Separat e t he joints and remove t he old panel.
Installation
1. Prepare t he new panel in t he areas where it is not fully welded andMIG plug weld these areas .
2. Prepare t he old and new p

Page 2548 of 3229

LAND ROVER FRELANDER 2 2006 Repair Manual 5. MIGPlugweld.
6. MIGPlugweld.

Page 2549 of 3229

LAND ROVER FRELANDER 2 2006 Repair Manual 7.Ins t allwelds tuds .
8. Inst all weld s tuds .
9. Dres s all welded joint s.
10. The inst allation of ass ociated panels and mechanical component sis t he revers e of removal.

Page 2550 of 3229

LAND ROVER FRELANDER 2 2006 Repair Manual Publi s hed: 11-May-2011
Front End Sheet Metal Repairs - Front Side Member
Removal and Inst all ati on
• NOTE: The front s ide member i s s erviced as a s eparate weld on panel. This procedure is

Publi s hed: 11-May-2011
Front End Sheet Metal Repairs - Front Side Member
Removal and Inst all ati on
• NOTE: The front s ide member i s s erviced as a s eparate weld on panel. This procedure is to fit a long s ect ion cut from thes ervice panel, dis carding t he rear part .
• NOTE: The s ervice panel is not ful ly wel ded.
• NOTE: The s ect ion must be made at leas t 20mm forward of the l aser wel d.
1. The front s i de member is replaced in conjuncti on wit h:
Front bumper cover
Front bumper
Hood lat ch panel
Both front fenders
Front bumper mount ing
Front s ide member clos ing panel
Fender apron panel front reinforcement
Fender apron l ower panel
• NOTE: It is al so neces sary t o remove t he engine and s us pens ion as an as s embly.
2. For addit ional informati on rel at ing to this repair procedurepleas e s ee t he foll owing:For addi ti onal informat ion, refer t o: Body and Frame (501-26Body Repai rs - Vehi cl e Speci fic Informat ion and ToleranceChecks , Descripti on and Operat ion) /Standard W orks hop Practi ces (100-00 General Informat ion,Des cript ion and Operat ion).
3. Remove the front s ide member clos ing panel.For addi ti onal informat ion, refer t o: Front Side Member Cl os i ngPanel (501-27 Front End Sheet Met al Repai rs , Removal andIns t allat ion).
4. Remove the radi ator cool ing pack.For addi ti onal informat ion, refer t o: Radiator (303-03A Engi neCooling - I6 3.2L Petrol, Removal and Ins tall ati on).
5. Remove the engine and front s uspens ion as an as s embly.
6. Rel eas e and lay as ide t he brake pipe.
7. LH Side: Release the bat tery juncti on box and posi ti on asi de.
8. LH Side: Remove the ai r int ake pi pe.
9. LH Side: Release and lay as ide t he brake pi pe at the si demember.
10. LH Side: Remove the ant i-Lock brake s ys tem (ABS) Module.For addi ti onal informat ion, refer t o: Anti -Lock Brake Syst em(ABS) Module (206-09A Ant i-Lock Control, Removal andIns t allat ion).
11. RH Side: Remove the winds hi eld was her res ervoir.For addi ti onal informat ion, refer t o: W i nds hiel d W as herRes ervoi r (501-16 W i pers and W as hers , Removal andIns t allat ion).
12. RH Side: Remove the engi ne mount ing bracket .For addi ti onal informat ion, refer t o: Engi ne Mount RH (303-01BEngine - TD4 2.2L Dies el, Removal and Ins tall ati on).
13. RH Side: Remove the fender apron brake pipes .
14. RH Side: Remove the fender apron A/C pipe.
15. Rel eas e and l ay as ide t he ins ulat ing mat eri al at t hebulkhead.
16. Rel eas e and l ay as ide t he wiring harnes s .

Page 2551 of 3229

LAND ROVER FRELANDER 2 2006 Repair Manual 17. Mil l out t he s pot wel ds.
18. Saw cut t he old panel at t he poi nt il lus trat ed. The cuts houl d be made at l east 20mm forward of t he l as er weld.
19. Separat e t he joi nt s and r

Page 2552 of 3229

LAND ROVER FRELANDER 2 2006 Repair Manual 2. Prepare and MIG pl ug weld the new panel in the areasi llus t rat ed, where it i s not full y welded.
3. Prepare t he old and new panel joi nt s urfaces.
4. Dri ll holes i n the new panel ready

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