LAND ROVER FRELANDER 2 2006 Repair Manual

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.

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. Prepare the old and new panel joint surfaces.
6. 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.
7. Tack weld the butt joints.
8. MIG braze the slots.
9. Dress the tack welds.
10. MIG weld the butt joints.
11. Dress all welded joints.

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Rear End Sheet Metal
Description and Operation
Rear end service panels
Ite m De scr iption
1 Inner quart er panel front
2 I nne r q ua rt e r p a ne l re a r
3 Inner quart er panel
4 Rear wheelhouse outer
5 W ater drain panel section
6 Re a r l a mp mount i ng pa ne l
7 Rear bumper cover
8 Rear bumper
9 Quart er panel
10 Back panel assembly
11 Back panel
12 Spare wheel well
13 Rear crossmember
14 Rear wheelhouse front extension
15 Re a r s i de me mbe r cl o s i ng pa ne l
16 Re a r s i de me mbe r uppe r s i de e xt e ns i on
17 Re a r s i de me mbe r l owe r s i de e xt e ns i on
18 Re a r s i de me mbe r s e ct i on

Ite m De scr iption
19 Inner quart er panel and wheelhous e
20 Re a r bumpe r mount i ng
21 Li ft gat e
Time schedules, rear end
The following schedules show the total time taken to replace single panels and also combinations of panels. The published
times include the removal of Mechanical, Electrical and Trim, (MET), items, plus paint times based on Metallic Clear Over
Base Paint, (blends to adjacent panels are not included). A corrosion protection time is included where appropriate.
The times were generated by Thatcham, (the Motor Insurance Repair Research Centre), and are to be used as a guide only,
based on new undamaged panels. Job allowances are not included, as a guide Thatcham recommend 0.3 hours to be added
to single panel times and 0.5 hours to be added to combination times.
Single panel timesP a n e l D e s c r ip t io n T ime s
Rear bumper cover5.1
Liftgate6.9
Rear l amp mount ing panelL/H 8.5
R/H 8.6
Back panel14.6
Quarter panelL/H 22.9
R/H 24.1
Headliner remove and install3.3
Liftgate screen remove and install1.4
Rear suspension assembly remove and install4.0
Fuel tank remove and install2.5
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
Rear bumper cover
Rear bumper
Liftgate
Rear l amp mount ing panel
Back panel
Quarter panel
Headliner remove and install
Liftgate screen remove and install
Total TimeL/H 44.3
R/H 45.3
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
Rear bumper cover
Rear bumper
Liftgate
Rear lamp mounting panel L/H and R/H
Back panel
Inner back panel assembly
Quarter panel L/H and R/H
Headliner remove and install
Liftgate screen remove and install
Total Time62.5
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
Rear bumper cover
Rear bumper
Liftgate
Back panel
Inner back panel assembly
Quarter panel
Spare wheel well
Rear crossmember
Re a r bumpe r mo unt i ng
Re a r s i de me mbe r s e ct i o n
Re a r s i de me mbe r cl os i ng pa ne l
Rear side member upper side extension
W at er drai n panel s ect i on
I nne r q ua rt e r p a ne l a nd whe e l a rch
Headliner remove and install
Liftgate screen remove and install
Fuel tank remove and install
Rear suspension assembly remove and install
Total TimeL/H 69.6
R/H 70.3

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
Rear bumper cover
Rear bumper
Liftgate
Back panel
Inner back panel assembly
Quarter panel L/H and R/H
Spare wheel well
Rear crossmember
Rear bumper mounting L/H and R/H
Re a r s i de me mbe r s e ct i o n L/H a nd R/H
Re a r s i de me mbe r cl os i ng pa ne l L/H a nd R/H
Rear side member upper side extension L/H and R/H
W at er drai n panel s ect i on L/H and R/H
I nne r q ua rt e r p a ne l a nd whe e l a rch L /H a nd R/H
Headliner remove and install
Liftgate screen remove and install
Fuel tank remove and install
Rear suspension assembly remove and install
Total Time95.9
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
Rear bumper cover
Rear bumper
Liftgate
Back panel
Inner back panel assembly
Rear l amp mount ing panel
Spare wheel well
Re a r bumpe r mo unt i ng
Re a r s i de me mbe r s e ct i o n
Re a r s i de me mbe r cl os i ng pa ne l
Rear side member upper side extension
Liftgate screen remove and install
Fuel tank remove and install
Rear suspension assembly remove and install
Total TimeL/H 47.1
R/H 47.1
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
Rear bumper cover
Rear bumper
Liftgate
Back panel
Inner back panel assembly
Rear lamp mounting panels L/H and R/H
Spare wheel well
Rear crossmember
Rear bumper mounting L/H and R/H
Liftgate screen remove and install
Fuel tank remove and install
Rear suspension assembly remove and install
Total Time43.9

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Quarter Panel
Removal and Installation
Removal
CAUTION: The quarter panel must be MIG slot brazed to the rocker panel inner reinforcement, which is DP600, (Dual
Phase steel). MIG plug we lds / spot w elds must not be use d in this are a.
• NOTE: The quarter panel is serviced as a separate weld-on panel.
• NOTE: There are NVH elements inside this panel, they are not serviced on the new panel. If damaged, a new element
will be required.
1. The quarter panel is replaced in conjunction with:
Rear bumper cover
Rear door
Quarter 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. 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
(501-19
Bumpe rs , Re mo va l a nd Ins t a l l a t i on).
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 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).
6. Re mo ve t he re a r d o o r s t ri ke r f ro m t he C-P i l l a r.
7. Remove the roof moulding, front and rear sections.
8. 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).
9. 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
Gl a s s (501-11 Glass, Frames and Mechanisms, Removal and
Installation).
10. 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).
11. 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 : Floor Console
(501-12
Instrument Panel and Console, Removal and Installation).
12. Remove the RH & LH rocker panel inner trims.
13. 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).
14. Re mo ve t he re a r ca rp e t s e ct i o n.
15. 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 Safe t y Bel t Sys t em, Removal and Ins t al l at i on).
16. Remove the liftgate aperture weatherseal.
17. Remove the forced air extraction grille.
18. 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).
19. Remove the rocker panel outer moulding.
20. Release and lay aside the wiring harness along the inner

quarter panel and back panel.
21. Release and lay aside the insulating material at the inner
quarter panel.
22. 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 Drai ni ng
(310-00
Fuel System - General Information, General Procedures).
23. 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 Fil l er Pi pe
(310-01A Fuel Tank and Lines - I6 3.2L Petrol, Removal and
Installation).
24. 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.
25. Mill out the spot welds.
26. 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 and the fuel filler on the RH.
Installation

1. Offer up and align the new panel and clamp into position,
overlapping the old panel. Saw cut 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. Drill holes in the new panel ready for MIG plug welding.

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. 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.
7. Remove the new panel.
8. Apply adhesive to the areas illustrated.
9. If necessary, renew the NVH element/s.

10. Apply sealer adhesive to the NVH elements.
11. Offer up the new panel and clamp into position.
12. Tack weld the butt joints.
13. Sp o t we l d .
14. MIG pl ug we l d.