wheel LAND ROVER FRELANDER 2 2006 Repair Manual

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Spare Wheel Well
Removal and Installation
Removal
• NOTE: The spare wheel well is serviced as a separate weld on panel, it includes the spare wheel retaining bracket but
not the crossmember.
• NOTE: The panel is serviced less its weld studs
1. The spare wheel well is replaced in conjunction with:
Rear bumper cover
Rear bumper
Back panel
Back panel assembly
Fuel t ank
Rear subframe and suspension assembly
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 back panel assembly.
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 : Back Panel
(501-30 Rear
End Sheet Metal Repairs, Removal and Installation).
4. Remove the rear subframe and suspension as an assembly.
5. Remove 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
(310-01A Fuel
Tank and Lines - I6 3.2L Petrol, Removal and Installation) /
Fuel Tank
(310-01B Fuel Tank and Li nes - TD4 2.2L Di es el,
Removal and Installation).
6. Remove the rear seat.
7. Remove the RH and LH rocker panel inner trims.
8. Remove the RH and LH rear quarter panel mouldings.
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 Panel
Moulding (501-08 Ext eri or Trim and Ornament at i on, Removal
and Installation).
9. Release and lay aside the carpet.
10. Remove the RH and LH brake pipes.
11. Release and lay aside the wiring harnesses at the floor panel
and inner quarter panels.
12. Mill out the spot welds.

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Rear Wheelhouse Outer
Removal and Installation
Removal
• NOTE: The rear wheelhouse outer is serviced as a separate weld-on panel.
1. The rear wheelhouse outer is replaced in conjunction with:
Rear bumper cover
Quarter panel
Rear door
Quarter glass
I nne r q ua rt e r p a ne l
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 mo ve t he i nne r q ua rt e r p a 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 : Inner Quart er Panel
(501-30 Rear End Sheet Metal Repairs, 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.

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Back Panel
Removal and Installation
Removal
• NOTE: The back panel is serviced as a separate weld-on panel, it includes the bumper retaining bracket.
• NOTE: It is necessary to remove sections of both rear lamp mounting panels to enable removal and refitment of the back
panel , (unl es s t he back panel i s being replaced i n conjunct i on wit h a rear l amp mount ing panel ).
1. The back panel is replaced in conjunction with:
Rear bumper cover
Rear bumper
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.
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 RH and LH bumper retainer guides.
5. Remove the liftgate aperture weatherseal.
6. Remove the back panel trim.
7. Remove t he RH and LH quart er panel i nner t ri ms .
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 Trim Panel
(501-05 Int eri or Trim and Ornament at i on, Removal and
Installation).
8. Remove the RH and LH forced air extraction grilles.
9. Remove the spare road wheel.
10. Remove the subwoofer amplifier.
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 : Subwoofer Amplifier
(415-01 Information and Entertainment System, Removal and
Installation).
11. Re move t he e xha us t a s s e mbl y.
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 : Exhaust Syst em
(309-00A
Exhaus t Sys t em - I6 3.2L Pet rol , Removal and Ins t all at ion).
12. Remove the floor panel exhaust heat shield.
13. Remove the RH and LH road wheels.
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).
14. Release and lay aside the insulating material at the back
panel.
15. Release and lay aside the back panel wiring harness.
16. Saw cut each rear lamp mounting panel, as illustrated.17. Mill out the spot welds.18. Separate the joints and remove the rear lamp mounting
panel sections, retain the sections for refitment.19. Mill out the spot welds.
20. Separate the joints and remove the old panel.
Installation
1. Prepare the old and new panel joint surfaces, including the
rear l amp mount i ng panel s ect ions .

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Rear Crossmember
Removal and Installation
Removal
• N O T E: T he re a r cro s s me mb e r i s s e rvi ce d a s a s e p a ra t e we l d -o n p a ne l .
• NOTE: The panel is serviced less its weld studs.
1. T he re a r cro s s me mb e r i s re p l a ce d i n co nj unct i o n wi t h:
Rear bumper cover
Re a r bumpe r a rma t ure
Back panel
Inner back panel assembly
Spare wheel well
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 spare wheel well.
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 : Spare Wheel W ell
(501-30
Rear End Sheet Metal Repairs, 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. Sp o t w e l d .

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Rear Wheelhouse Front Extension
Removal and Installation
Removal
• NOTE: The rear wheelhouse front extension is to be unpicked from the rear wheelhouse outer service panel.
1. The rear wheelhouse front extension is replaced in conjunction
with:
Rear bumper cover
Quarter panel
Rear door
Quarter glass
I nne r q ua rt e r p a ne l
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 mo ve t he i nne r q ua rt e r p a 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 : Inner Quart er Panel
(501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
4. Mill out the spot welds.
5. Separate the joints and remove the old panel.
Installation

1. Remove the rear wheelhouse front extension from the
wheelhouse outer service panel.
2. Prepare the old and new panel joint surfaces.
3. Drill holes in the new panel ready for MIG plug welding.
4. 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.

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Inner Quarter Panel and Wheelhouse
Removal and Installation
Removal
• NOTE: The inner quarter panel and wheelhouse is an assembly of the inner quarter panel, rear wheelhouse inner, rear
wheelhous e out er and t he rear lamp mount ing panel.
• NOTE: The service panel is not fully welded.
• NOTE: The panel is sectioned to avoid disturbing the roof panel.
1. The inner quarter panel and wheelhouse is replaced in
conjunct ion wit h:
Rear bumper cover
Rear bumper
Quarter panel
Rear door
Quarter glass
Rear subframe and suspension assembly
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 quarter 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 : Quarter Panel
(501-30
Rear End Sheet Metal Repairs, Removal and Installation).
4. Remove the rear subframe / suspension as an assembly.
5. Remove the brake pipe.
6. RH Only: Release and lay aside the fuel vent hose.
7. Remove the rear seat backrest.
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 Backres t Heat er
Ma t (501-10 Seating, Removal and Installation).
8. Release and lay aside the wiring harness.

Publ is hed: 11-May-2011
Uni-Body, Subframe and Mounting System - Front SubframeRemoval and Installation
S p e c ia l T o o l( s )
211-316
Se p a ra t o r, B a l l Jo i nt
502-012
Alignment Pins, Subframe
General Equipment
P o we rt ra i n Ja ck
Removal
1. WARNING: Make sure to support the vehicle with axle stands.
Raise and support the vehicle. 1.
Siphon the fluid from the power steering reservoir. 2.
Remove the front road wheels and tires.
Refer to: W heel and Tire
(204-04 W heels and Tires , Removal and Ins t all at i on). 3.
Remove the engine undershield.
Refer to: Engine Undershield
(501-02 Front End Body Panel s, Removal and
Installation). 4.
Di sconnect t he LH cat al ys t monit or sens or elect ri cal connect or. 5.

18. WARNING: Make sure that a new steering column flexible coupling bolt is
installed.
Connect the steering column to the steering gear.
Torque: 25 Nm18.
Connect and s ecure t he cat alys t moni t or s ens or el ect ri cal connect ors . 19.
Install the 2 subframe mounting bolts and remove the jack. 20.
Install the engine undershield.
Refer to: Engine Undershield
(501-02 Front End Body Panel s, Removal and
Installation). 21.
Install the wheels and tires.
Refer to: W heel and Tire
(204-04 W heels and Tires , Removal and Ins t all at i on). 22.
Refill and bleed the power steering.
Refer to: Power Steering System Bleeding
(211-00 St eeri ng Sys t em - General
Informat ion, General Procedures). 23.
Using only four wheel alignment equipment approved by Land Rover, check and adjust
the wheel alignment. 24.

6.
Repeat the above procedure on the opposite hand. 7.
8.
Repeat the above procedure on the opposite hand. 9.
10.
WARNING: Make sure to support the vehicle with axle
stands.
Raise and support the vehicle. 10.
Remove both rear wheels and tires.
Refer to: Wheel and Tire
(204-04 Wheels and Tires, Removal and
Installation). 11.
If installed, remove the rear suspension height sensor.
Refer to: Rear Suspension Height Sensor
(204-05 Vehi cl e Dynami c
Suspension, Removal and Installation). 12.
Remove the rear muffler.
Refer to: Exhaus t Sys t em
(309-00B Exhaus t Sys t em - TD4 2.2L
Diesel, Removal and Installation). 13.