LAND ROVER FRELANDER 2 2006 Repair Manual

(501-20B Suppl ement al Res t rai nt Sys t em, Removal and
Installation).
17. 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).
18. Release and lay aside the front carpet section.
19. Re mo ve t he re a r ca rp e t s e ct i o n.
20. Remove the roof moulding, front and rear sections.
21. Remove the front 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).
22. Remove the rocker panel outer moulding.
23. Release and lay aside the insulating material at the inner
bulkhead.
24. Release and lay aside the wiring harnesses at the A-Pillar,
B-Pillar and rocker panel.
25. Remove the fender mounting bracket:
Mil l out 3 s pot welds . If not re-us i ng t he mount ing t he
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.
26. Saw cut the old panel at the A-Pillar and rocker panel,
us i ng t he ne w p a ne l f o r re f e re nce , e ns uri ng t ha t t he ne w
panel overlaps the panel remaining on the vehicle.

27. Saw cut the old panel at the B-Pillar, as illustrated,
observe the measurements to allow access to the B-Pillar
re i nf o rce me nt .
28. Mill out the spot welds.
29. Se p a ra t e t he j o i nt s a nd re mo ve t he o l d p a ne l , a l s o re l e a s i ng
the NVH elements.
Installation
1. Offer up and align the new panel and clamp into position,
overlapping the old panel remaining on the vehicle. Check
al ignment , i f correct , proceed t o next s t ep, i f not , rect i fy and
recheck before proceeding.
2. Saw cut t hrough t he new and old panels at t he rocker panel
and A-Pillar, where the MIG butt joints are to be made.

3. Saw cut t hrough t he new and old panels at t he 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. Prepare the old and new panel joint surfaces.
7. If necessary, renew the NVH element/s.

8. Apply sealer adhesive to the NVH element at the A-Pillar.
9. Apply sealer adhesive to the NVH element at the B-Pillar.
10. Apply adhesive to the A-Pillar as illustrated.
11. Offer up the new panel and clamp into position.
12. Tack weld the butt joints.

13. MIG braze the slots.
14. Dress the tack welds.
15. MIG weld the butt joint at the upper B-Pillar.

16. MIG weld the butt joints at the A-Pillar and rocker panel.
17. Dress all welded joints.
18. The installation of associated panels and mechanical
components is the reverse of removal.

Publ is hed: 11-May-2011
Side Panel Sheet Metal Repairs - A-Pillar Outer Panel
Removal and Installation
Removal
CAUTION: The A-Pillar outer panel must be MIG slot brazed to the reinforcement, which is DP600, (Dual Phase steel).
MIG plug we lds / spot we lds, must not be used.
• NOTE: The A-Pillar outer panel is serviced as a separate weld-on panel. The fender mounting bracket 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 A-Pillar out er panel is replaced in conjunct ion wit h:
Front bumper cover
Hood
Front fender
Front 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 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).
7. 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).
8. 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).
9. Remove t he upper and l ower door hi nges from t he pi l lar, 4 x
bolts.
10. Re mo ve t he ro cke r p a ne l i nne r t ri m.
11. 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).
12. Remove the front 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).
13. Remove the rocker panel outer moulding.
14. Release and lay aside the front carpet section.
15. Re mo ve t he re a r ca rp e t s e ct i o n.
16. Remove the roof moulding, front and rear sections.
17. Release and lay aside the wiring harness along the A-Pillar
i nne r a nd i nne r ro cke r p a ne l .
18. Release and lay aside the insulating material at the inner
bulkhead.

19. Remove the fender mounting bracket:
Mil l out 3 s pot welds . If not re-us i ng t he mount ing t he
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.
20. Saw cut the old panel at the points illustrated, using the
ne w p a ne l f o r re f e re nce , e ns uri ng t ha t t he ne w p a ne l
overlaps the panel remaining on the vehicle.
21. Mill out the spot welds.
22. Se p a ra t e t he j o i nt s a nd re mo ve t he o l d p a ne l , a l s o re l e a s i ng
the NVH element.
Installation

1. Offer up and align t he new panel and clamp int o pos it ion,
overlapping the old panel remaining on the vehicle. Saw cut
through the new and old panels at the points where the MIG
butt joints are to be made.
2. Remove the new panel and the old remnants.
3. Prepare the old and new panel joint surfaces.
4. 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.
5. 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.

6. Remove the new panel.
7. Apply adhesive to the areas illustrated.
8. If necessary, renew the NVH element.
9. Apply sealer adhesive to the NVH element.
10. Offer up the new panel and clamp into position.
11. Tack weld the butt joints.