2006 LAND ROVER FRELANDER 2 engine

(Ignit ion). The forward facing light s ensor moni tors the ambi ent light l evel at the front of t he vehi cl e; the rearward facingli ght sens or moni tors t he li ght l evel coming from t he rear of the vehicle. W hen li ght from the rear of the vehicle exceedst he ambient li ght l evel from the front of t he vehi cl e, the aut omat ic di mmi ng circuit darkens t he i nt eri or mirror s urface.
Automat ic di mmi ng is i nhi bit ed when revers e gear is sel ect ed to provide t he dri ver wi th maximum vis ion. On vehicles wi thautomat ic t rans mis s ion, t he revers e gear s ignal i s provided by t he TCM vi a t he high s peed Cont rol ler Area Net work (CAN)bus to the CJB. The CJB then provi des a power feed t o t he mirror. On vehicles wi th manual t rans mis s ion, the revers e gears ignal is provi ded by a t ransmis s ion s wit ch t hat i s hardwi red t o t he CJB.
Cabin Humidity Sensor
Dependi ng on the vehicl e s pecificati on, t he automat ic di mmi ng int erior mirror may als o i ncorporate a cabi n humidi tys ens or. The cabin humi dit y s ens or is locat ed i n the mirror rear cas ing near to the wi nds hiel d, and provi des the ATC modul ewit h i nformati on regarding the probabil it y of winds hield mis t ing. Thi s i nformat ion is us ed to vary t he automat ic operat ionof the cl imat e cont rol s yst em.For addit ional informat ion, refer t o: Cont rol Component s (412-01 Cli mat e Cont rol , Descripti on and Operat ion).
EXTERIOR MIRRORS
Electricall y operated and heated ext eri or mirrors are i nst all ed as s tandard. Depending on the s pecifi cat ion and trim level oft he vehi cl e, t he followi ng opti ons are available:
Power fold (s wit ch pack operat ed feat ure) and auto fol d (remote hands et operated feature)Memory recallRevers e gear mirror dipExteri or mirror l amps.
The power fold/aut o fold feature is avail abl e only when power fol d mi rrors are i ns t alled to t he vehicle.
The auto fold and revers e gear mirror dip functi ons are not cus t omer confi gurable, but may be enabled or dis abled by t hedeal er usi ng the Land Rover approved di agnos ti c s ys t em. The diagnos t ic s ys tem enabl es or di sabl es ei ther or bothfuncti ons by s et t ing t he EEPROM cont ained wi thin the ins trument cl us t er.
The LH door mirror i ncorporat es an ambi ent ai r temperat ure sens or that is hardwired to the ECM. The ECM is connected tot he CJB and ot her cont rol modules via the hi gh s peed CAN bus . The s ensor provides i nformati on to the ECM that is thent ransmit ted on the medi um s peed CAN bus for us e by ot her control modul es. O n vehi cl es ins tal led wi th a high-lineins t rument clus ter, t he CJB t rans mit s t he temperature s ignal t o t he ins t rument clus ter t hat provi des a dis play of t heambient t emperature t o the driver.
For addit ional informat ion, refer t o:
Elect roni c Engi ne Cont rol s - 2.2L Dies el (303-14 Electronic Engine Controls - 2.2L Dies el, Des cript ion and Operat ion),Informat ion and Mes s age Cent er (413-08 Informati on and Mes sage Cent er, Descripti on and Operat ion).
The exteri or mirror l amps are controll ed by the interior li ght ing funct ion.For addit ional informat ion, refer t o: Int eri or Li ght ing (417-02 Interior Lighti ng, Des cri pt ion and Operati on).
Exterior Mirror Adjustment

6
-St art control modul e
PRINCIPLES OF OPERATION
Front Power Operated Non-Memory Seats
The dri ver's non-memory s eat wil l operate i n all i gni ti on power modes . The pas senger non-memory seat wi ll only operat e
when t he ignit ion i s i n power mode 6 (Ignit ion).
Power for front pas s enger s eat operat ion is s upplied from t he AJB via a pas s enger s e at power relay t o t he pas s enger s eat
cont rol s wit ch pack. Power for t he driver's s eat operat ion is s upplied di rectl y from the AJB t o t he dri ver's s eat cont rol
s wit ch pack. The front pas s enger and dri ver s eat power suppli es are controlled by th e CJB. The s eat s wi tch pack direct s the
volt age to t he relevant s eat adjus tment mot or when a s eat control swit ch is pres s ed. Two pins wi thin each of t he s eat
s wit ch packs cont rol t he s eat motors. Bot h pins are normal ly connect ed to ground.
The dri ver and pas senger s wit ch packs are al s o connected i n circui t wit h a bat tery-s aver t imer relay t hat i s located in, and
cont rol led by t he CJB. The bat tery-s aver t imer relay all ows operati on of the driver and pas s enger s eat cont rols for 10
mi nut es aft er the engine is s wit ched off, and the i gni ti on is then s elected t o an ap propriat e power mode. The 10 minute
t imer is res et if t he appropriat e i gni ti on power mode is retai ned and the driver's d oor i s opened or clos ed. The driver and
pass enger s eat operati on is inhibit ed i mmediat el y fol lowi ng cent ral locking of t he v ehi cl e.
Operat ing a seat mot or control swit ch appli es volt age to one of t he pins whi le t he o t her pi n remai ns connect ed t o ground.
Operat ing t he s eat motor cont rol s wit ch in the oppos it e direct ion reverses the power and ground connecti ons to the mot or,
all owing t he mot or pi ni on t o rot ate in t he oppos i te di recti on. In t he event t hat a m ot or sei zes or s t icks , an i nternal
t hermal cut -out s wit ch wil l trip to remove volt age from t he mot or.
Driver's Power Operated Memory Seat
The dri ver's memory s eat wil l operat e when t he i gni ti on is in power modes 4 (Acces so ry) and 6 (Ignit ion), and wi ll not
operate during power mode 9 (Engine crank).
Power for the driver's memory s eat operat ion i s s uppl ied di rectl y from t he AJB t o t h e power s eat module. The memory s eat
s wit ch pack i s connected t o t he power seat module that cont rol s t he operati on and me mory pos it ion of t he i ndi vi dual s eat
mot ors . The power s eat module i s connected on the medi um s peed CAN bus t o t he CJB an d the front LH and RH door
cont rol modules .
The power seat module is als o connect ed in ci rcuit wi th a batt ery-saver ti mer rel ay that is locat ed wi thin, and controlled by
t he CJB. The batt ery-saver ti mer rel ay allows operat ion of t he s eat cont rols for 10 mi nut es aft er the engine is s wi tched off,
and t he ignit ion i s t hen sel ect ed to an appropri at e power mode. The 10 minut e t imer i s res et if t he appropri at e i gni ti on
power mode is retai ned and the driver's door i s opened or clos ed. The driver's s eat operat ion is i nhi bit ed immedi ately
fol lowing cent ral locki ng of the vehicl e.
Reques t s for memory exterior mirror movements for a memory recal l are t rans mit ted on the medi um s peed CAN bus by t he
power seat module to t he front door control modul es. The front door cont rol modules direct ly control the memory s t ore and
recall pos it ions for t he memory ext eri or mirrors.
For addit ional informat ion, refer t o: Rear Vi ew Mi rrors (501-09 Rear View Mirrors , Des cript ion and Operat ion).
Power Seat Mod ule
The power seat module features driver s electable funct ions , and aut omat ic monit ori ng functi ons .
Driver Selectable Functions
Seat and ext erior mirror memory recall Immediat e s eat adjus t ment.
Seat and exterior mirror memory recall function
The memory recall functi on s ets t he driver's seat t o a s t ored pos it ion, and is acti v at ed when a swi tch pack memory
posi ti on butt on is pres sed. W hen memory recal l i s i ni ti ated, only 2 seat adjus tment mot ors wil l operat e at any one t ime to
li mit the overall current cons umpti on. To furt her minimize t he current l oad as the m otors energize, the i nit iati on of each of
t he 2 operati ng mot ors i s phas ed wi th a 10 mill is econd del ay. The cushi on s lide and backres t wil l move fi rs t , foll owed by
t he cus hion height .
As s oon as t he seat s wit ch pack memory pos it ion but ton is pres s ed, a mes sage i s t ran s mit ted by the power s eat modul e
on t he medium s peed CAN bus to the front door control modul es. The door cont rol modu les t hen act ivat e t he memory
recall pos it ions for t he exteri or mirrors. The i nst rument clus t er mess age cent er wil l di s pl ay memory recall mes s ages when
a memory recall i s acti vat ed.
The memory recall functi on operates wit h 2 s eparate modes; t he operat ion of each mod e is dependant on t he vehicle
s tat us when the seat memory posi ti on butt on is pres sed.
Memory recall operati ng modes:
One-t ouch mode Proport ional mode.
One-Touch Mode
W hen t he vehicle i s s tat ionary and a s wit ch pack memory pos it ion butt on i s pres sed, t he memory recall functi on wil l
operate in 'one-touch' mode. One t ouch mode all ows the seat and exterior mirrors t o immediatel y move t o t he request ed
s tored memory pos i ti on.
If a s eat adjus t ment or memory pos it ion but ton i s operat ed during memory recal l 'one -t ouch' mode, t he current memory
recall wi ll be cancell ed and t he seat (and ext eri or mirrors via t he medium s peed CAN bus) wi ll i mmediat el y s top movi ng.
The s eat will t hen commence movi ng in the di recti on that corresponds to the press ed s wi tch.

ItemPart NumberDescription1-Emergency key bl ade2-Headl amp delay funct ion but ton3-Vehicl e l ock button4-Vehicl e unlock button5-Li ftgate unlock butt on6-Panic alarm buttonThe remote hands et is a seal ed wat erproof uni t t hat contains a Printed Ci rcuit Board (PCB), transponder and a rechargeablebattery. The remote hands et batt ery i s charged whenever the remote hands et is located i n the s tart cont rol unit , and t heengi ne is running.
The remote hands et cont ai ns an emergency key blade, conceal ed in t he key fob. The emergency key bl ade i s us ed to acces sthe vehicle through the LH front door i f t he central locki ng syst em fai ls. The emergency key bl ade is als o us ed t o enable ordis able t he rear door chil d locks , and t o dis able t he pas senger ai rbag.For addit ional informat ion, refer t o: Ai r Bag and Safet y Belt Pretens ioner Supplement al Rest raint Sys tem (SRS) (501-20BSupplemental Res traint Sys tem, Des cription and Operat ion).
The remote hands et is identi cal for all vehicl e s peci ficat ions, but di ffers in t he pres et frequency and power that the remotehandset operates. The remot e handset for each vehicle specificat ion is ident ifi ed by a s uffix change to the base part numberas follows:
Part No. SuffixOperating FrequencyVehicle SpecificationA#433 MHzEurope and ROW (Rest Of W orld)B#315 MHzNASC#315 MHz low powerJapan and KoreaEach remot e handset features a uni que ident ifi cation code that is programmed within t he integral trans ponder. The RF si gnalproduced by t he remot e handset contains t he uni que ident ifi cation code and also a rolli ng code. Duri ng vehicl e product ion,the unique identification codes of the valid remot e handsets are programmed int o the CJB, and the roll ing codes are al sosynchronized wi th the CJB.
W hen the remote handset is operat ed, t he CJB checks t he unique i dent ificat ion and rol ling code. The CJB will only respond ifthe RF si gnal produced is from a val id remote hands et for the vehicle.For addit ional informat ion, refer t o: Anti -Theft - Pas si ve (419-01 Anti -Theft - Pas si ve, Des cript ion and Operati on).
A tot al of 30 'sl ots ' are availabl e in the CJB s oftware to al low for repl acement, and the addi tion of remote hands et s. Inservi ce, t he Land Rover approved di agnost ic system may be us ed to communicat e wit h the CJB for the followi ng:
Identi ficati on of remote handset all ocat ion wit hin t he CJB.Enabli ng of new remot e handsets .Disabl ing of exist ing remote handsets .Re-enabling a previ ously disabled remot e handset.
If the remote hands et rolling code l os es synchronizati on with t he CJB, t he remot e handset funct ions will not operate.Synchronizati on between the remote hands et and CJB is rest ored by s tart ing t he engine wit h t he affect ed remot e handset,and all owing the engine to run for a minimum of 6 mi nutes.
Addi tional buttons are located on the remote hands et to provide convenience operati on of t he li ftgat e rel ease, headlampdelay and panic al arm functions .

wi ll double lock the vehicle to dis engage the interior and ext erior handles , and will arm the active and pass ive ant i-t heftsystem. For additi onal informat ion, refer to:
Ant i-Theft - Active (419-01A Anti -Theft - Active, Des cri pti on and Operation),Ant i-Theft - Pass ive (419-01 Ant i-Theft - Pass ive, Description and Operat ion).
Central Locking System - Automatic Modes
The central locking s ys tem feat ures automat ic modes to control t he vehicl e entry points , and provi de prot ection for t hesystem components.
The central locking s ys tem incorporates the fol lowing automati c modes:
Misl ock modeSpeed dependant locking mode (i f programmed)Cras h unlocki ng modeRepeti tion bl ocking modeLockout protect ion modeAutomat ic relock mode (if programmed)Transport mode.
Mislock Mode
A mi slock occurs i f t he CJB receives an ext ernal lock or double lock reques t when a hi nged panel is ajar. To indicat e ami slock t he CJB sounds t he horns to produce a 100 milli second 'chirp'.
If a mi slock occurs due t o an external lock reques t when a hinged panel is ajar, t he CJB will not carry out a lock reques t onany acces s points .
Speed Dependant Locking Mode
W hen speed dependant l ocking is enabled the CJB wil l i nt ernal ly lock al l t he doors when t he vehicl e speed exceeds 8 km/h(5 mph) wit h al l the doors closed and the engine running. If the dri ver or front passenger door is opened and then cl os ed,when t he vehicl e s lows down or s tops and then increases to more t han 8 km/h (5 mph) again, the CJB wi ll int ernally lock thedoors.
Speed dependant locki ng may be enabled or dis abled by the deal er us ing the Land Rover approved diagnost ic syst em.
Crash Unlocking Mode
W ith the ignit ion in power mode 6 (Ignit ion), if a cras h occurs that tri ggers deployment of t he air bags , t hen t he CJB willunlock al l of t he doors . The CJB is informed of the crash by a s tatus mess age from the Rest raint s Cont rol Modul e (RCM) onthe medi um s peed CAN bus t hat changes from 'no crash' t o 'crash'.
The central locking s ys tem will als o perform crash unl ocking mode i f a 'no cras h' status mes sage is not received from t heRCM every 500 mi llis econds .For addit ional informat ion, refer t o: Ai r Bag and Safet y Belt Pretens ioner Supplement al Rest raint Sys tem (SRS) (501-20BSupplemental Res traint Sys tem, Des cription and Operat ion).
Repetition Blocking Mode
To prot ect the central locki ng s yst em motors and actuat ors against syst em mi s-use, the CJB i ncorporat es repeti tion bl ockingto limi t t he maximum operati ng rate of each mot or and actuator. The lock mot or in each door lat ch also i ncorporat es thermalprotect ion.
Central Locking System Motor and Actuator Operating ParametersMotor orActuatorCurrent On T ime(ms)Maximum Operations (perminute)Nominal Operating Current(A)Stall Current(A)Li ftgat e lat ch600 ± 10103.6 to 5.27.5Fuel fi ller door700 ± 1052.78Door doubl e l ock100 to 110100.281.14Door lock100 to 110100.543.31Lockout Protection Mode
The vehicle is not able to be locked us ing a front door central l ocking butt on or i ns trument panel central l ocking swit ch if anydoor is open.
If an internal lock reques t is recei ved from ei ther of the front door central locking but tons , t he CJB will cent rally lock thevehicle and then centrall y unl ock the vehicle if any door is open.
If a front door i s open and the open door central locki ng butt on i s press ed and held i n t he locked pos it ion, the open frontdoor may remai n i n the l ocked s tate. W hen t he open door is subs equently clos ed, the CJB will centrally unl ock all doors.
Automatic Relock Mode
Automati c rel ock prevent s accidental operation of the remote hands et but tons that will unlock and disarm t he vehicl e.
W hen the central locki ng s yst em is unlocked us ing the remote handset, and a door or l iftgate is not opened or t he remot ehandset is not placed in the s tart cont rol uni t wit hin 1 minut e, the CJB wi ll automatical ly lock or double l ock t he vehicl eagai n, depending on the previous ly locked mode.
Transport Mode
Al l new vehicl es are delivered from the factory in transport mode. Trans port mode replaces the t radit ional t ransi t rel ay andinhibits a number of el ectri cal s ys tems and features t o reduce quiescent drain from the batt ery during delivery. When t hevehicle is in t rans port mode 'trans p' is displayed in the i ns trument clust er odometer. Si ngle point ent ry is enabled and gl oballocki ng and unlocking usi ng t he remot e handset i s dis abled.

t o the 'Owners Handbook'.
Rear Screen Wiper
On recei vi ng a reques t for rear s creen wi per operat ion the CJB wi ll energize relay RA2 i n t he AJB. W hen energized, relayRA2 provides a feed t o t he rear s creen wiper mot or. The rear s creen wi per operat es int ermi tt entl y, wi th a delay betweenwipes of approximat ely 6 seconds . The CJB cont rol s operati on of rel ay RA2, and consequentl y rear s creen wiper mot oroperati on, accordingly.
The CJB als o provi des a feed t o t he rear s creen wi per mot or park s wit ch. The park s wit ch is i ntegral wi th the rear s creenwiper mot or and ens ures t he wi per returns to the park pos i ti on if t he rear wi per reques t is cancel led mid-st roke. The parks wit ch cont act s are cl osed when the rear wiper is i n any posi ti on except t he park pos it ion. Thi s all ows the CJB to returnt he rear wiper t o t he park pos it ion when relay RA2 i s de-energized.
The CJB wil l als o power the rear screen wiper motor i f revers e gear is s elected whi le the wi nds hiel d wi per funct ion i sact ive. On vehicles fit t ed wit h an aut omat ic trans mi s si on, t he reverse gear s ignal origi nat es in the Transmis si on ControlModule (TCM). The TCM broadcas ts a revers e gear s ignal over the hi gh s peed CAN bus to the CJB, which responds byoperati ng t he rear wiper.
On vehicles fit ted wit h a manual transmis s ion, the revers e gear s i gnal ori ginates at t he revers e gear s wit ch. The reversegear s wi tch i s hardwired t o t he CJB.
Windshield Washers
On recei vi ng a reques t for wi nds hiel d was her operat ion t he CJB wi ll energize t he front washer cont rol relay. Thi s all ows abatt ery volt age feed t o flow to the was her pump. A ground path for t he pump is provided by t he de-energized rear was hercont rol rel ay. Bot h was her control relays are int egral wit h t he CJB.
W hen wi ndshi el d was her operat ion i s reques ted, t he winds hi eld was hers will operat e. The CJB will delay wiper operati onfor 100 ms aft er the was her swi tch i s pres s ed. If t he s wit ch is pres s ed for l ess than 100 ms, t he CJB wil l not operat e t hewipers.
The CJB wil l power t he wi nds hield wipers for as l ong as washer operati on is reques t ed, al though t he washers wil l ti me outaft er 10 s econds. After t he was her s wi tch has been rel eas ed, the CJB wi ll operat e t he winds hi eld wipers t hrough 2 morewipe cycles .
Rear Screen Washer
On recei vi ng a reques t for rear s creen was her operati on the CJB wi ll energize the rear was her cont rol rel ay. This al lows abatt ery volt age feed t o flow to the was her pump. A ground path for t he pump is provided by t he de-energized front was hercont rol rel ay. Revers ing the polarit y of the pump (s ee 'W i nds hield W as hers ' above) allows was her fl uid t o be di rected t ot he rear s creen washer jet rather t han the windshi el d was her jets . The rear s creen was her jet is incorporat ed int o the hi ghmounted s t op lamp.
The rear s creen was her wi ll operat e for up t o 10 seconds if cont inuousl y reques ted. W hen rear s creen was her operati on isreques ted, the rear screen wiper wil l operat e conti nuous ly unt il t he s wit ch is released. After t he swit ch has been released,or fol lowing 10 seconds of conti nuous operat ion, the CJB will operat e t he rear s creen wiper t hrough 2 or 3 more wi pecycles .
Headlamp Washers
W hen t he vehicle ent ers i gni ti on mode 4 (acces s ory) to 7 (engine running) the firs t winds hield was h reques t great er than100 ms will operat e a headlamp power was h s equence. The CJB will t hen s tart a 10 mi nut e t imer. If 5 request s forwinds hield washer operati on are made wit hin this 10 mi nut e wi ndow, t he CJB wil l power t he headl amp was hers uponreceiving the fifth reques t . W hen t his occurs , the 10 minute ti mer is res et t o 0.
If the CJB receives no windshi el d was her reques t s duri ng a 10 mi nute window, the headlamp was hers will operat e on t hefi rs t reques t received aft er the 10 minut e window has el aps ed. Agai n, once t he headlamp was hers have been operati onal ,t he CJB res ets t he t imer t o 0.
The headl amp was hers wi ll only operat e when t he headl amps are on. The CJB receives a 'li ght s on' si gnal from the lightcont rol module over t he LIN bus .
W hen headlamp was her operati on is required, t he CJB energizes rel ay 9 in the BJB, all owing a bat tery vol tage feed t opower the headlamp was her pump. A ground path for t he washer pump i s provided by t he de-energi zed relay 12, which i sals o l ocat ed in the BJB. Thi s s equence of event s provides was her flui d t o the headlamp 1 was her jets .
Aft er thi s s equence the power s uppl y t o t he pump is revers ed. The CJB does t his by de-energi zing rel ay 9 and energi zi ngrel ay 12. Thi s allows the pump to provi de was her flui d to the headlamp 2 was her jets. The s equence of event s runs asfol lows :
Power to headlamp 1 was her - 500 msDelay t o power headl amp 2 was her - 100 msPower to headlamp 2 was her - 500 msDelay (s oak ti me) to power 1 headlamp washer - 700 msPower to 1 headl amp was her - 500 msDelay t o power 2 headl amp was her - 100 msPower to 2 headl amp was her - 500 ms
If there is l ess than 1 l it er (0.26 US gall on) of was her flui d in the was her fl uid reservoi r, t he CJB wil l s us pend headl ampwas her operat ion. The fl uid l evel s wit ch is hardwired to the CJB, which als o t rans mits a low fl ui d s ignal to the i nst rumentclus ter over t he medi um s peed CAN bus. For addit ional i nformati on, refer to:
Ins trument Clus ter (413-01 Ins t rument Clus t er, Descripti on and Operat ion),Informat ion and Mes s age Cent er (413-08 Informati on and Mes sage Cent er, Descripti on and Operat ion).

ItemPart NumberDescription
1-Drivers s afet y belt pret ensi oner2-Pas senger safety belt pretens ioner
3-Inst rument clus ter
4-Engine Control Modul e (ECM)5-Belt -minder sens or – market s peci fi c
6-Safet y belt t ens i on sens or – market s peci fi c
7-Batt ery8-Occupancy s ens or
9-Occupancy s ens or module
10-Central Junct ion Box (CJB)11-Res traints Cont rol Module (RCM)

• NOTE: The s ame reference point s mus t be chos en on bot h s ides when checking for changed dimens ions (e.g.bores , edges , beads /s wage l ines etc).
All of t he important external body dimens ions are li st ed in Tol erance Checks .For addit ional informat ion, refer t o: Body and Frame (501-26 Body Repai rs - Vehi cl e Speci fi c Informat ion andTolerance Checks , Descripti on and Operat ion).
Measurements wi th a meas uri ng/s trai ghtening jig.A meas uri ng/s traightening ji g is required for accurat e meas urement s of the body. The measuring s yst ems arecat egoris ed by t heir means of operati on:Mechanical meas uring s ys tem.Opti cal meas uri ng s ys t em.
Quick and accurate meas uri ng res ult s can be obtai ned usi ng comput eri sed meas uring s yst ems .
A minimum of t hree int act meas uri ng point s on t he body are requi red for meas urement s of length, wi dth and hei ghtdimens ions .
In s ome cases t his may mean making t he meas uri ng poi nts access ibl e. Al l of thes e meas uring sys tems can be used t omake body meas urements , provided al l t he equipment is avail able.
Planning a repair
The fol lowing decis i ons have t o be made before t he repai rs are s tarted:
Does the vehicl e need to be put on a s traightening ji g, or can it be st rai ght ened by other means ?Does the body need t o be meas ured?Do aggregates l ike engine or axles need t o be removed?• NOTE: It is preferable to repair body part s rat her t han t o renew them, as t his keeps the complet e body-s hel lint act .
W hi ch body parts need t o be renewed?W hi ch body parts can be repai red?
Obtaining spare parts
The avai labil it y of s pare part s oft en determines how eas il y t he body repairs can be carri ed out . The fol lowi ng procedure isrecommended:
Obtai n all t he data for the vehicl e, i ncl udi ng t ype, vehi cl e i dent ificati on number, trim code, engine i dent ificati onlet ters, i nit ial regis t rat ion et c.Es tabli sh all of the metal part s that need t o be renewed.Es tabli sh all of the at tached part s t hat need t o be renewed, including smal l parts li ke ri vet s, cl ips etc.
Straightening repairs
W ARNING: The us e of heat when pull ing t o s traighten body panels , (s uch as s ide members ), i s not recommended.Longi tudinal pulli ng, (hot or col d), is al s o not recommended. A smal l amount of s ide to si de pull is permis s ibl e, (col d).
W hen any t ype of pul li ng or st rai ght ening operat ion i s performed i t is i mport ant to obs erve for any movement i n adjacentpanel s.
A panel must retai n it s s t rength and integrit y, i f there is any doubt the panel mus t be renewed.
Straightening repairs are often required to res tore the body t o i ts origi nal s hape aft er an accident. This can be done wit h:
Ali gnment jigs .Univers al s trai ghtening and meas uri ng ji gs.W el di ng jig s ys tem.
The fol lowing poi nts mus t be foll owed to ens ure that t he repairs are carri ed out profes si onal ly and t hat all t he dimens ionsare correct aft er t he repai rs have been carri ed out.
Struct ure:- The repair s equence depends on the individual repair plan (t aki ng any neces sary dis as sembl y work intoaccount).- Clean t he at tachment areas .- Anchor t he vehi cl e free of s tres s on t he relevant s ys t em.- Support the aggregat es to take s train off the body.- Decide on at l eas t t hree meas uri ng/mounti ng poi nts that are undamaged and as far apart as pos s ible (forbasi c adjus tment ).- Check the di mens i ons of t he meas uri ng/mounti ng poi nts .Straightening:-• NOTE: Check di mensi ons and gaps conti nuous ly during s t raight eni ng.
A body i s always s traightened i n the oppos it e direct ion t o t hat of the i mpact . Always carry out st rai ght eningrepairs wi th the complet e body s hel l as s embled (do not cut out any part s beforehand). Carry out t hes traightening work i n s everal s t ages . This prevents the ris k of over st ret chi ng or of welded joi nts t eari ng out .Duri ng the individual st rai ght ening s t eps , rel ieve t ens i on by s triking wi th an aluminium hammer whi le the part iss ubject ed t o a t ensi le load (in t he area of pre-determined folding poi nt s , dent s , welded joi ns etc.).Speci al feat ures :- Ult ra high s t rength st eel cannot be st rai ght ened due to it s bri tt lenes s and mus t always be repl aced.
Cutting out body parts

Publi s hed: 11-May-2011
Body Repairs - Vehicle Specific Information and Tolerance Checks - Body
and Frame
Des cript ion and Operat ion
Front End Body Dimensions
• NOTE: All di mens i ons shown are in mil li metres (mm).
• NOTE: Dimens i ons s hown t o holes , are al ways taken from/to the hole cent re. They are al so always t o the body panels urface, not to the t op of bolt s or components .
ItemFromT oDimension
AHead l amp i nboard fi xing holeFender, forward fixi ng hol e1291.3
BTrans mi s si on LH mount ing, forward s t udEngine RH mounti ng forward fixing hol e922CTrans mi s si on LH mount ing, rear s tudEngine RH mounti ng forward fixing hol e957.5
DTrans mi s si on LH mount ing, rear s tudEngine RH mounti ng middl e fi xing hole922.3
ETrans mi s si on LH mount ing, rear s tudEngine RH mounti ng forward fixing top s t ud924.8FTrans mi s si on LH mount ing, rear s tudDamper mounti ng, rear hol e1025.4