LAND ROVER FRELANDER 2 2006 Repair Manual

18. Use a belt sander to remove 5 x spot welds.
19. Mill out the remaining spot welds.
20. 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
al ignment , i f correct , proceed t o next s t ep, i f not , rect i fy and
recheck before proceeding.
4. Sp o t we l d .

5. MIG P l ug we l d.
6. Install weld studs.
7. Dress all welded joints.
8. 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 Reinforcement
Removal and Installation
Removal
• NOTE: The fender apron panel reinforcement has to be unpicked from the fender apron panel service panel, it is not
available separately.
• NOTE: The RH panel is serviced less its weld studs 1. T he f e nd e r a p ro n p a ne l re i nf o rce me nt i s re p l a ce d i n
conjunct ion wit h:
Front bumper cover
Hood lat ch panel
Both front fenders
Fender apron upper 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 the fender apron upper 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 Upper Panel
(501-27 Front End Sheet Met al Re pai rs , Removal and
Installation).
4. Remove the front shock absorber.
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 Shock Abs orber
(204-01 Front Suspension, Removal and Installation).
5. LH Side: Remove the engine support insulator.
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 : Engine Upper Support
Insulator (303-01B Engi ne - TD4 2.2L Di es el, Removal and
Installation).
6. LH Side: Remove the bat tery t ray.
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 : Battery Tray
(414-01
Battery, Mounting and Cables, Removal and Installation).
7. LH Side: Remove the air intake pipe.
8. LH Side: Release the battery junction box and position aside.
9. RH Side: Remove the windshield washer reservoir.
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 Washer
Res ervoi r (501-16 W i pers and W as hers , Removal and
Installation).
10. RH Side: Remove the engine mounting bracket.
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 : Engine Mount RH
(303-01B
Engine - TD4 2.2L Diesel, Removal and Installation).
11. RH Side: Release the coolant expansion tank and lay it
aside.
12. RH Side: Evacuate the A/C system.
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 : Air Conditioning (A/C)
System Recovery, Evacuation and Charging (412-00 Cl i mat e
Co nt ro l Sys t e m - Ge ne ra l I nf o rma t i o n, Ge ne ra l P ro ce d ure s ).
13. RH Side: Remove the fender apron A/C pipes.
14. RH Side: Release and lay aside the insulating material at the
bulkhead.
15. Release and lay aside the wiring harness.

16. Mill out the spot welds.
17. 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
al ignment , i f correct , proceed t o next s t ep, i f not , rect i fy and
recheck before proceeding.
4. Sp o t w e l d .

5. MIG P l ug we l d.
6. Install weld studs.
7. Dress all welded joints.
8. 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 Extension
Removal and Installation
Removal
• NOTE: The fender apron panel front extension has to be unpicked from the fender apron panel, it is not serviced
separately.
1. The fender apron panel front extension is replaced in
conjunct ion wit h:
Front bumper cover
Hood lat ch panel
Both front fenders
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 hood l at ch 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 : H o o d L a t ch P a ne l (501-27,
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. 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.
3. Spot weld at the points illustrated.
4. Dress all welded joints.
5. 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 Lower Panel
Removal and Installation
Removal
• NOTE: The fender apron lower panel is to be removed from the fender apron panel service panel; it is not available
separately.
• NOTE: The panel is serviced less its weld studs
1. T he f e nd e r a p ro n l o we r p a ne l i s re p l a ce d i n co nj unct i o n w i t h:
Front bumper cover
Hood lat ch panel
Both front fenders
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 hood l at ch 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 : H o o d L a t ch P a ne l (501-27,
Removal and Installation).
4. Use a belt sander to sand down the spot welds in the area
illustrated.
5. Mill out the remaining spot welds.
6. 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
al ignment , i f correct , proceed t o next s t ep, i f not , rect i fy and
recheck before proceeding.
4. MIG P l ug we l d.
5. Sp o t w e l d .6. Install weld stud.
7. Dress all welded joints.
8. 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 Upper Panel
Removal and Installation
Removal
• NOTE: The fender apron upper panel is s erviced as a s eparat e weld-on panel.
• NOTE: The service panel is not fully welded.
• NOTE: There is an NVH element attached inside this panel, it is not serviced on the new panel. Therefore, if damaged, a
new element will be required.
1. The fender apron upper panel is replaced in conjunct ion wit h:
Front bumper cover
Hood
Hood lat ch panel
Both front fenders
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 hood l at ch 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 : H o o d L a t ch P a ne l (501-27,
Removal and Installation).
4. Remove the hood.
5. Remove the plenum chamber 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 : Plenum Chamber
(412-01
Climate Control, Removal and Installation).
6. LH Side: Remove the air intake pipe.
7. RH Side: Release and lay aside the wiring harness.
8. Remove t he hood hi nge, 2 x 13mm headed bol t s .
9. Mill out the spot welds.