LAND ROVER FRELANDER 2 2006 Repair Manual

C o mb in a t io n p a n e l r e p la c e me n t t ime s
C o mb in atio n p an el times
P a n e l D e s c r ip t io n T ime s
Door front
Front fender
Total TimeL/H 8.9
R/H 8.9
C o mb in atio n p an el times
P a n e l D e s c r ip t io n T ime s
Door rear
Quarter panel
Headliner remove and install
Total TimeL/H 27.0
R/H 28.3
C o mb in atio n p an el times
P a n e l D e s c r ip t io n T ime s
Door front
Door rear
B-Pillar outer panel
B-Pillar reinforcement
B-Pillar inner panel
Headliner remove and install
Total TimeL/H 39.0
R/H 39.2
C o mb in atio n p an el times
P a n e l D e s c r ip t io n T ime s
Door front
Door rear
Front fender
Quarter panel
Headliner remove and install
Total TimeL/H 32.2
R/H 33.5
C o mb in atio n p an el timesP a n e l D e s c r ip t io n T ime s
Door front
Front fender
A-Pillar outer panel
A-Pillar reinforcement
I ns t rume nt p a ne l re mo ve a nd I ns t a l l
Headliner remove and Install
Windshield glass remove and Install
Total TimeL/H 37.2
R/H 37.5

Publis hed: 11-May-2011
Side Panel Sheet Metal Repairs - Side PanelRemoval and Installation
Removal
CAUTION: The side panel must be MIG slot brazed to its reinforcement, which contains DP600, (Dual Phase steel). MIG plug
w e lds / spot w e lds, must not be use d.
• NOTE: The side panel 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 is replaced in conjunct ion wit h:
Front bumper cover
Front fender
Hood
Front door
Rear door
Quarter glass
Instrument panel
Windshield glass
Headliner
Rear bumper cover
2. For additional information relating to this repair procedure 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 General Informat ion,
Description and Operation).
3. Remove t he 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 t he 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
Ornamentat ion, Removal and Inst all at ion) /
Headliner - Vehicles With: Tilting Roof Opening Panel
(501-05
Interior Trim and Ornamentation, Removal and Installation).
8. Re mo ve 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 : Inst rument Panel - TD4 2.2L
Di es e l (501-12 Inst 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 rear quarter 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 : Rear Quarter Window Glass
(501-11 Glass, Frames and Mechanisms, Removal and Installation).
11. Re move t he re a r bumpe r co ve 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 : Rear Bumper Cover
(501-19
Bumpe rs , Re mo va l a nd I ns t a l l a t i o n).
12. Remove the upper and lower door hinges from the A-Pillar, 4 x
bolts.
13. Remove the upper and lower door hinges from the B-Pillar, 4 x
bolts.
14. Remove the front door striker from the B-Pillar.
15. Remove the rear door striker from the C-Pillar.
16. Remove the roof moulding, front and rear sect ions .
17. 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 Supplement al Res t raint Syst em, Removal and

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.

41. Saw cut the old panel at the A-Pillar and rear quarter panel, using
t he new panel for reference, ensuri ng t hat t he new panel overlaps
the panel remaining on the vehicle.
42. Saw cut the old panel at the B-Pillar, as illustrated, observe the
measurements to allow access to the B-Pillar reinforcement.
43. Mill
out
the
spot
welds.
44. Separate the joints and remove the old panel, also releasing the
NVH elements.
Installation
1. Offer up and align t he new panel and clamp into pos iti on,
overlapping the old panel remaining on the vehicle. Check
alignment, if correct, proceed to next step, if not, rectify and
re che ck b e f o re p ro ce e d i ng .

2. Saw cut the new and old panels at the A-Pillar and rear quarter
panel, ensuring that the new panel overlaps the panel remaining
on the vehicle.
3. Saw cut through the new and old panels at the B-Pillar, where the
MIG butt joint is to be made.
4. Remove the new panel and the old remnants.
5. NOTE: MIG slots should be installed in accordance with the spacing
shown in the illustration. Where this is not possible, due to the
indents in the panel, the slot should be made in the location of the
original spot weld.
Cut slots in the new panel ready for MIG brazing.

6. Drill holes in the new panel ready for MIG plug welding.
7. Prepare the old and new panel joint surfaces.
8. If necessary, renew the NVH element/s.
9. Apply sealer adhesive to the NVH element at the A-Pillar.
10. Apply sealer adhesive to the NVH element at the B-Pillar.

11. Apply sealer adhesive to the NVH elements at the quarter panel.
12. Apply adhesive to the A-Pillar as illustrated.
13. Apply adhesive to the quarter panel as illustrated.
14. Offer up the new panel and clamp into position.
15. Tack weld the butt joints.

16. MIG pl ug we l d.
17. Sp o t w e l d .

18. MIG bra z e t he s l o t s .
19. Dress the tack welds.
20. MIG weld the butt joint at the upper B-Pillar.
21. MIG weld the butt joints at the A-Pillar and quarter panel.
22. Dress all welded joints.
23. The installation of associated panels and mechanical components
i s t he re ve rs e o f re mo va l .

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