LAND ROVER FRELANDER 2 2006 Repair Manual

10. Separate the joints and remove the old panel, including its
NVH element.
Installation
1. Prepare and spot weld the new panel in the areas
illustrated, where it is not fully welded.
2. Prepare the old and new panel joint surfaces.

3. Drill holes in the new panel ready for MIG plug welding.
4. Offer up the new panel and clamp into position. Check
al ignment , i f correct , proceed t o next s t ep, i f not , rect i fy and
recheck before proceeding.
5. Re move t he pa ne l a nd a ppl y a dhe s i ve t o t he a re a s
illustrated.
6. If necessary, renew the NVH element.
7. Apply sealer adhesive to the NVH element.
8. Offer up the new panel and clamp into position.

9. Spot weld at the points illustrated.
10. MIG Pl ug we l d.
11. Dress all welded joints.
12. The installation of associated panels and mechanical
components is the reverse of removal.

Publ is hed: 11-May-2011
Front End Sheet Metal Repairs - Front Side Member Closing Panel
Removal and Installation
Removal
• NOTE: The front side member closing panel must be unpicked from the front side member and suspension top mount
assembly, it is not serviced separately.
• NOTE: The panel is serviced less its weld studs
1. The front side member closing panel is replaced in conjunction
with:
Front bumper cover
Front bumper
Hood lat ch panel
Both front fenders
Front bumpe r mount i ng
Fender apron l ower panel
Fender apron panel front reinforcement
Front s i de me mbe r
• NOTE: It is also necessary to remove the engine and suspension as an assembly.
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Re move t he f ront s i de me mbe r.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Front Side Member
(501-27
Front End Sheet Metal Repairs, Removal and Installation).
4. Mill out the spot welds.
5. Saw cut the old panel at the point illustrated.
6. Separate the joints and remove the old panel.

Installation
1. Remove the panel from the service panel.
1. Mill out the spot welds.
2. Saw cut, ensuring the cut aligns with the one
a l re a dy ma de o n t he ve hi cl e .
2. Prepare the old and new panel joint surfaces.
3. Drill holes in the new panel ready for MIG plug welding.
4. Offer up the new panel and clamp into position. Check
al ignment , i f correct , proceed t o next s t ep, i f not , rect i fy and
recheck before proceeding.
5. W ith panels clamped into position:
1. Tack weld the butt joint.
2. MIG pl ug wel d.
6. Dress the tack welds.

7. MIG weld the butt joint.
8. Install weld stud.
9. Dress all welded joints.
10. The installation of associated panels and mechanical
components is the reverse of removal.

Publ is hed: 11-May-2011
Front End Sheet Metal Repairs - Fender Apron Panel Front Reinforcement
Removal and Installation
Removal
• NOTE: The fender apron panel front reinforcement has to be removed from the fender apron panel service panel; it is not
available as a separate panel.
• NOTE: The panel is serviced less its weld studs
1. The front side member and fender apron panel is replaced in
conjunct ion wit h:
Front bumper cover
Front bumper
Hood
Hood lat ch panel
Both front fenders
Fender apron l ower panel
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Remove t he fender apron l ower panel .
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Fender Apron Lower Panel
(501-27 Front End Sheet Met al Re pai rs , Removal and
Installation).
4. Mill out the spot welds.
5. Separate the joints and remove the old panel.
Installation
1. Prepare the old and new panel joint surfaces.

2. Drill holes in the new panel ready for MIG plug welding.
3. Offer up the new panel and clamp into position. Check
alignment, if correct, proceed to next step. If not, rectify and
recheck before proceeding.
4. MIG P l ug we l d.
5. Install weld studs.
6. Dress all welded joints.
7. The installation of associated panels and mechanical
components is the reverse of removal.

Publ is hed: 11-May-2011
Roof Sheet Metal Repairs - Roof
Description and Operation
Roof service panels
Ite m De scription
1Roof panel
2 Roof rear panel
3 Roof front panel
Time schedules, roof panels
The following times relate to the replacement of the roof panels as single panels. The published times include the removal
of Mechanical, Electrical and Trim, (MET), items, plus paint times based on Metallic Clear Over Base Paint, (blends to
adjacent panel s are not i ncl ude d). A corros i on prot ect i on t i me i s i ncl ude d where appropri at e .
The times were generated by Thatcham, (the Motor Insurance Repair Research Centre), and are to be used as a guide only,
based on new undamaged panels. Job allowances are not included, as a guide Thatcham recommend 0.3 hours to be added
to single panel times.
Single panel timesP a n e l D e s c r ip t io n T ime s
Roof panel20.3
Roof rear panel16.4
Roof front panel14.4

Publ is hed: 11-May-2011
Roof Sheet Metal Repairs - Roof PanelVehicles Without: Sliding Roof
Opening Panel
Removal and Installation
Removal
• NOTE: The roof is serviced as a separate weld on panel, less its reinforcements.
• NOTE: Along the RH and LH sides of the panel, spot welds should be installed adjacent to the originals and not in the
same locations.
1. The roof panel is replaced in conjunction with:
Liftgate
Windshield
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Disconnect both battery cables.
4. Remove the liftgate.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Liftgate
(501-03 Body
Closures, Removal and Installation).
5. Remove the windshield glass.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Windshield Glass
(501-11
Glass, Frames and Mechanisms, Removal and Installation).
6. Remove both front seats.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Front Seat
(501-10
Seating, Removal and Installation).
7. Remove the rear seat.
8. Remove bot h side air curt ain modules.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Side Air Bag Module
(501-20B Suppl ement al Res t rai nt Sys t em, Removal and
Installation).
9. Remove both front safety belt retractors.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Front Safety Belt Retractor
(501-20A Safe t y Bel t Sys t em, Removal and Ins t al l at i on).
10. Remove both rear safety belt retractors.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Rear Safety Belt Retractor
(501-20A Safe t y Bel t Sys t em, Removal and Ins t al l at i on).
11. Release and lay aside the wiring harness.