sensor LAND ROVER FRELANDER 2 2006 Repair Manual

Publi s hed: 11-May-2011
Supplemental Restraint System - C-Pillar Side Impact Sensor
Removal and Inst all ati on
Removal
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
Di sconnect t he bat t ery ground cable.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -
General Informat ion, Specificati ons).
1.
Make t he SRS s ys t em s afe.
Refer t o: Standard W orks hop Pract ices (100-00 General Informat ion,
Des cript ion and Operat ion).
2.
Remove t he rear quart er t ri m panel.
Refer t o: Rear Quarter Tri m Panel (501-05 Int erior Tri m and
Ornament ati on, Removal and Ins tal lat ion).
3. T orque:
10 Nm 4.
Installation To i nst all , revers e t he removal procedure.
1.

Publi s hed: 11-May-2011
Supplemental Restraint System - Front Impact Severity Sensor
Removal and Inst all ati on
Removal
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
Di sconnect t he bat t ery ground cable.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -
General Informat ion, Specificati ons).
1.
Make t he SRS s ys t em s afe.
Refer t o: Standard W orks hop Pract ices (100-00 General Informat ion,
Des cript ion and Operat ion).
2. T orque:
10 Nm 3.
Installation To i nst all , revers e t he removal procedure.
1.

Installation).
18. Remove the front seat.
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 Seat ing,
Removal and Installation).
19. Remove the floor console.
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 : Fl oor Cons ol e
(501-12
Instrument Panel and Console, Removal and Installation).
20. Remove the RH & LH rocker panel inner trims.
21. Remove the rear seat cushion.
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 Seat Cushion
(501-10
Seating, Removal and Installation).
22. Re mo ve t he re a r ca rp e t s e ct i o n.
23. Remove the B-Pillar side impact sensor.
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 : B-Pillar Side Impact Sensor
(501-20B Supplement al Res t raint Syst em, Removal and
Installation).
24. Remove the front safety belt retractor.
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 Safet y Belt Sys t em, Removal and Ins t al lat ion).
25. Remove the rear safety belt retractor.
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 Safet y Belt Sys t em, Removal and Ins t al lat ion).
26. Release and lay aside the front carpet section.
27. Re mo ve t he re a r ca rp e t s e ct i o n.
28. Remove the front wheel and tire. LINK
29. Remove the rear wheel and tire.
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 : Wheel and Tire
(204-04
Wheels and Tires, Removal and Installation).
30. Remove the rocker panel out er mouldi ng.
31. Remove the liftgate aperture weatherseal.
32. Remove the forced air extraction grille.
33. Release and lay aside the insulating material at the inner
bulkhead.
34. Release and lay aside the insulating material at the inner quarter
panel.
35. Release and lay aside the wiring harnesses at the A-Pillar,
B-Pillar and rocker panel.
36. Release and lay aside the wiring harness along the inner quarter
panel and back panel.
37. Release and lay aside the insulating material at the inner quarter
panel.
38. RH side: Drain the fuel tank.
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 : Fuel Tank Draining
(310-00
Fuel Sys t em - General Informat ion, General Procedures).
39. RH side: Remove the fuel tank filler pipe.
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 : Fuel Tank Filler Pipe
(310-01A
Fuel Tank and Lines - I6 3.2L Petrol, Removal and Installation).
40. Remove the fender mounting bracket:
Mill out 3 spot welds. If not re-using the mounting the upper
spot weld does not have to be removed.
Separate the mounting from the A-Pillar.
Retain the mounting if it is being reused, if not, discard.

Publ is hed: 11-May-2011
Side Panel Sheet Metal Repairs - Side Panel Front Section
Removal and Installation
Removal
CAUTION: The side panel front section must be MIG slot brazed to its reinforcement, which contains DP600, (Dual
Phase steel). MIG plug we lds / spot w elds, must not be use d.
• NOTE: The side panel front section is serviced as a separate weld on panel, serviced less the fender mounting bracket,
which is serviced separately.
• NOTE: There are NVH elements attached inside this panel, they are not serviced on the new panel. If damaged, new
element/s will be required.
1. The s ide panel front s ect ion is replaced in conjunct ion wit h:
Front bumper cover
Front fender
Hood
Front door
Rear door
Instrument panel
Windshield glass
Headliner
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 the hood.
4. Remove the front fender.
5. Remove the front door.
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 Door
(501-03 Body
Closures, Removal and Installation).
6. Remove the rear door.
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 Door
(501-03 Body
Closures, Removal and Installation).
7. Remove the headliner.
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 : Headliner - Vehicles
Without: Tilting Roof Opening Panel (501-05 Int eri or Tri m and
Ornamentation, Removal and Installation) /
Headliner - Vehicles With: Tilting Roof Opening Panel
(501-05
Int erior Trim and Ornamentat ion, Removal and Installat ion).
8. Re move t he i ns t rume nt pa ne l .
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 : Instrument Panel - TD4
2.2L Di es el (501-12 Ins t rument Panel and Cons ole, Removal
and Installation).
9. 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).
10. Remove the upper and lower door hinges from the A-Pillar, 4
x bol t s .
11. Remove the upper and lower door hinges from the B-Pillar, 4
x bol t s .
12. Remove the front door striker from the B-Pillar.
13. Re mo ve t he s i d e a i r curt a i n mo d ul e .
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 : Si d e A i r Curt a i n Mo d ul e
(501-20B Suppl ement al Res t rai nt Sys t em, Removal and
Installation).
14. Remove the rear seat cushion.
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 Seat Cushion
(501-10
Seating, Removal and Installation).
15. Remove the RH & LH rocker panel inner trims.
16. Remove the B-Pillar side impact sensor.
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 : B-Pillar Side Impact Sensor

Publ is hed: 11-May-2011
Side Panel Sheet Metal Repairs - B-Pillar Outer Panel
Removal and Installation
Removal
CAUTION: The B-Pillar outer panel must be MIG slot brazed to the B-Pillar reinforcement, which is BH300, (Bake
Hardened steel) and the rocker panel inner reinforcement, which is DP600, (Dual Phase steel). MIG plug we lds / spot
we lds, must not be used.
• NOTE: The B-Pillar outer panel is serviced as a separate weld-on panel.
• NOTE: There is an NVH element attached inside this panel, it is not serviced on the new panel. If damaged, a new
element will be required.
• NOTE: If the B-Pillar outer is replaced without the B-Pillar reinforcement, the upper section butt joint can be made lower
down the pillar if required.
1. The B-Pillar out er panel is replaced in conjunct ion wit h:
Front door
Rear door
Headliner
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 the front door.
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 Door
(501-03 Body
Closures, Removal and Installation).
4. Remove the rear door.
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 Door
(501-03 Body
Closures, Removal and Installation).
5. Remove t he upper and l ower door hi nges from t he B-Pi l lar, 4 x
bolts.
6. Remove the front door striker from the B-Pillar.
7. Remove the front seat.
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).
8. Remove the rear seat cushion.
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 Seat Cushion
(501-10
Seating, Removal and Installation).
9. Remove the front safety belt retractor.
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 t he headli ner.
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 : Headliner - Vehicles
Without: Tilting Roof Opening Panel (501-05 Int eri or Tri m and
Ornamentation, Removal and Installation) /
Headliner - Vehicles With: Tilting Roof Opening Panel
(501-05
Int erior Trim and Ornamentat ion, Removal and Installat ion).
11. Remove the RH & LH rocker panel inner trims.
12. Remove the B-Pillar side impact sensor.
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 : B-Pillar Side Impact Sensor
(501-20B Suppl ement al Res t rai nt Sys t em, Removal and
Installation).
13. Re mo ve t he s i d e a i r curt a i n mo d ul e .
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 : Si d e A i r Curt a i n Mo d ul e
(501-20B Suppl ement al Res t rai nt Sys t em, Removal and
Installation).
14. Remove the roof moulding, front and rear sections.
15. Remove the rocker panel outer moulding.
16. Release and lay aside the front carpet section.
17. Re mo ve t he re a r ca rp e t s e ct i o n.
18. Release and lay aside the wiring harness along the B-Pillar
i nne r a nd i nne r ro cke r p a ne l .

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).
22. Re mo ve t he re a r ca rp e t s e ct i o n.
23. Release and lay aside the front carpet section.
24. Remove the B-Pillar side impact sensor.
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 : B-Pillar Side Impact Sensor
(501-20B Suppl ement al Res t rai nt Sys t em, Removal and
Installation).
25. Remove the C-Pillar side impact sensor.
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 : C-Pillar Side Impact Sensor
(501-20B Suppl ement al Res t rai nt Sys t em, Removal and
Installation).
26. Release and lay aside the bulkhead inner insulation.
27. Release and lay aside the wiring harness along the inner
ro cke r p a ne l .
28. Saw cut the old panel at its joints with the A-Pillar, B-Pillar
and quart er panel, ens uring t here is an allowance for t he
new panel to overlap. Use the new panel for reference.
29. Mill out the spot welds.
30. Separate the joints and remove the old panel.
Installation
1. Offer up and align the new panel and clamp into position,
overlapping the old panel remaining on the vehicle.
2. Saw cut t hrough t he new and old panels at t he A-Pillar,
B-Pillar and quarter panel, where the MIG butt joints are to
be made.
3. Remove the new panel and the old remnants.

Disconnect the RH catalyst monitor sensor electrical connector. 6.
Rel eas e t he cat al ys t monit or sens or wiri ng harness . 7.
8. CAUTION: Make sure that the ball joint ball does not rotate.
Disconnect both front stabilizer bar links from the lower suspension arm. 8.

6.
Repeat the above procedure on the opposite hand. 7.
8.
Repeat the above procedure on the opposite hand. 9.
10.
WARNING: Make sure to support the vehicle with axle
stands.
Raise and support the vehicle. 10.
Remove both rear wheels and tires.
Refer to: Wheel and Tire
(204-04 Wheels and Tires, Removal and
Installation). 11.
If installed, remove the rear suspension height sensor.
Refer to: Rear Suspension Height Sensor
(204-05 Vehi cl e Dynami c
Suspension, Removal and Installation). 12.
Remove the rear muffler.
Refer to: Exhaus t Sys t em
(309-00B Exhaus t Sys t em - TD4 2.2L
Diesel, Removal and Installation). 13.

1. CAUTION: Make sure that new bolts are installed.
Clean the component mating faces.
With assistance, install the subframe.With assistance, align and secure the differential.Tighten the rear bolts.
Torque: 110 Nm
Tighten the front bolts.
Torque: 175 Nm
1.
2.
CAUTION: Make sure that new bolts are installed.
Align the suspension arms to the subframe and install the bolts, do
not fully tighten at this stage. 2.
Using the special tool, support the subframe. 3.
Connect the transmission breather lines. 4.
5. CAUTIONS:
Make sure that no components catch.
Make sure that new bolts are installed.
With assistance, position the subframe to the body and tighten the
bolts.
Torque: 175 Nm
5.
6.
CAUTION: Make sure that new bolts are installed.
Install the stabilizer clamp bolts, but do not tighten fully at this
stage. 6.
Connect the Active On-demand Coupling module electrical connector. 7.
Re mo ve t he p o we rt ra i n j a ck.
General Equi pment : P o w e rt ra i n Ja ck
8.
9.
CAUTION: Make sure that new bolts are installed.
Install the trailing arm to body brackets.
Torque: 110 Nm9.
10.
CAUTION: Make sure that the brake hose is not twisted
and is correctly located.
Clean the component mating faces.
Install the brake caliper anchor plate.
Torque: 110 Nm
Repeat the above procedure for the other side.
10.

Secure the wheel speed sensor and lead.
11.

Torque: 5 NmSecure the lead in the clips.Repeat the above procedure for the other side.
LH side: Connect the ride height sensor electrical connector. 12.

Position and secure the rear shock absorbers.
Install both mass dampers.
Torque: 25 Nm
Repeat the above procedure for the other side.
13.
14. CAUTION: Make sure that new bolts are
installed.
Clean the component mating faces.
Connect the driveshaft to the rear flange.
Torque: 40 Nm
14.
Install the parking brake cables to the guide tubes. 15.
Connect the parking brake cables. 16.
Adjust the parking brake.
Refer to: Parking Brake Cable Adjustment
(206-05 Parki ng Brake and
Act uat i on, General Procedures ). 17.
Install the rear muffler.
Refer to: Exhaus t Sys t em
(309-00B Exhaus t Sys t em - TD4 2.2L
Diesel, Removal and Installation). 18.
Install the rear quarter trim panels.
Refer to: Rear Quarter Trim Panel
(501-05 Int eri or Tri m and
Ornament at i on, Removal and Ins t al lat i on). 19.
Install the rear suspension height sensor.
Refer to: Rear Suspension Height Sensor
(204-05 Vehi cl e Dynami c
Suspension, Removal and Installation). 20.
Install the wheels and tires.
Refer to: Wheel and Tire
(204-04 Wheels and Tires, Removal and
Installation). 21.