LAND ROVER FRELANDER 2 2006 Repair Manual

Publi s hed: 11-May-2011
Front End Sheet Metal Repairs - Front End Sheet Metal
Des cript ion and Operat ion
Front end s ervice panels
ItemDescription
1Hood l atch panel2Fender apron upper panel
3Fender apron panel front ext ensi on
4Fender apron panel rei nforcement5Sus pens ion top mount
6Fender apron panel
7Front s ide member and sus pens i on top mount as s embly8Front s ide member cl osi ng panel
9Front s ide member secti on
10Fender apron lower panel11Front s ide member
12Fender apron panel front reinforcement
13Front bumper mounti ng14Front bumper
Time schedules, front end
The fol lowing schedul es s how the tot al t ime t aken t o repl ace si ngl e panels and als o combi nat ions of panel s. The publi s hedt imes i ncl ude the removal of Mechani cal , El ect ri cal and Trim, (MET), i tems , plus paint t imes bas ed on Met all ic Clear OverBase Pai nt, (blends to adjacent panels are not included). A corrosi on prot ect ion t ime is included where appropriate.
The t imes were generated by That cham, (the Mot or Ins urance Repai r Research Cent re), and are t o be us ed as a gui de onl y,based on new undamaged panels . Job al lowances are not included, as a guide Thatcham recommend 0.3 hours to be addedt o s ingle panel ti mes and 0.5 hours t o be added to combi nat ion t imes.
Single panel timesPanel DescriptionT imes
Hood5.6
Front bumper cover5.5Front fender5.5
Hood l at ch panel6.2
Engine and Sus pens ion as s embly remove and ins tal l8.5Inst rument panel remove and ins t al l6.2
Combination panel replacement times
C ombination panel times

Panel DescriptionT imes
Hood
Front bumper coverFront bumper
Hood l at ch panel
Front fenderFender mount ing bracket, (front )
T otal T imeL/H 16.5R/H 16.5
C ombination panel times
Panel DescriptionT imes
HoodFront bumper cover
Front bumper
Hood l at ch panelFront fender L/H and R/H
Front fender mounti ng bracket , (front ) L/H and R/H
T otal T ime17.2
C ombination panel timesPanel DescriptionT imes
Hood
Front bumper coverFront bumper
Hood l at ch panel
Front fenderFront fender mounti ng bracket , (front )
Front bumper mount ing
Front s ide memberFront s ide member and s us pens ion top mount as s embl y
Fender apron upper panel
Engine and s us pens ion as s embly remove and ins tal lInst rument panel remove and ins t al l
T otal T imeL/H 42.2R /H 43.6
C ombination panel times
Panel DescriptionT imes
HoodFront bumper cover
Front bumper
Hood l at ch panelFront fender L/H and R/H
Front fender mounti ng bracket , (front ) L/H and R/H
Front bumper mount ing L/H and R/HFront s ide member L/H and R/H
Front s ide member and s us pens ion top mount as s embl y L/H and R/H
Fender apron upper panel L/H and R/HEngine and s us pens ion as s embly remove and ins tal l
Inst rument panel remove and ins t al l
T otal T ime57.6
C ombination panel timesPanel DescriptionT imes
Hood
Front bumper coverFront bumper
Hood l at ch panel
Front fenderFront fender mounti ng bracket , (front )
Front bumper mount ing
Front s ide member s ecti onFender apron lower panel
Fender apron panel front reinforcement
Engine and s us pens ion as s embly remove and ins tal l
T otal T imeL/H 29.9R/H 30.0

Publi s hed: 11-May-2011
Front End Sheet Metal Repairs - Front Bumper Mounting
Removal and Inst all ati on
Removal
• NOTE: The front bumper mount ing i s s erviced as a s eparat e weld-on panel .
• NOTE: Due t o t he combi ned thi cknes s of the panels , it i s recommended t hat s pot welds are repl aced wi th MIG plug wel dsin thi s repair.
1. The front bumper mounti ng is replaced in conjuncti on wit h:
Front bumper cover
Front bumper
Hood lat ch panel
Both front fenders
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 hood l at ch panel .For addi ti onal informat ion, refer t o: Hood Latch Panel (501-27,Removal and Ins tall ati on).
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. LH Side: Remove the ai r int ake pi pe.
6. RH Side: Remove t he 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).
7. Rel eas e and lay as ide t he wiring harnes s .
8. Mil l out t he s pot wel ds.

9. Mil l out t he s pot welds .
10. Separat e t he joi nt s and remove the panel.
Installation
1. Prepare t he old and new panel joi nt s urfaces.
2. Dri ll holes in the new panel ready for pl ug weldi ng.
3. Offer up the new panel and clamp i nto pos it ion. Checkali gnment , if correct , proceed to next s tep, i f not , recti fy andrecheck before proceeding.
4. Plug weld to the front s ide member.

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.

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 .

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 panel joint s urfaces .
3. Drillholes int he newpanelreadyfor MIGplugwelding.
4. O ffer up t he new panel and clamp int o posit ion. Check alignment,if correct , proceed t o next st ep, if not , rect ify and recheck beforeproceeding.

5. MIGPlugweld.
6. MIGPlugweld.

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.

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 .