Frelander 2. Manual - part 648

 

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Frelander 2. Manual - part 648

 

 

Side Panel Sheet Metal Repairs - Side Panel Sheet Metal

Description and Operation

Side service panels

Item

Description

1

B-Pillar inner panel

2

B-Pillar reinforcement

3

Side  panel

4

B-Pillar outer panel

5

A-Pillar outer panel

6

Front door

7

Rear  door

8

Rocker  panel

9

Side panel front section

10

Rocker panel inner reinforcement

11

A-Pillar reinforcement

paragraph

Time schedules, side panels

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 times

Panel Description

Times

Front fender

5.5

Door front

6.9

Door rear

6.6

Rocker panel

L/H 22.8

R/H 22.7

Quarter panel

L/H 22.9

R/H 24.1

Instrument panel remove and install

6.2

Headliner remove and install

3.3

Windshield glass remove and install

1.9

Combination panel replacement times

Combination panel times

Panel Description

Times

Door front
Front fender
Total Time

L/H 8.9

R/H 8.9

Combination panel times

Panel Description

Times

Door rear
Quarter panel
Headliner remove and install
Total Time

L/H 27.0

R/H 28.3

Combination panel times

Panel Description

Times

Door front
Door rear
B-Pillar outer panel
B-Pillar reinforcement
B-Pillar inner panel
Headliner remove and install
Total Time

L/H 39.0

R/H 39.2

Combination panel times

Panel Description

Times

Door front
Door rear
Front fender
Quarter panel
Headliner remove and install
Total Time

L/H 32.2

R/H 33.5

Combination panel times

Panel Description

Times

Door front
Front fender
A-Pillar outer panel
A-Pillar reinforcement
Instrument panel remove and Install
Headliner remove and Install
Windshield glass remove and Install
Total Time

L/H 37.2

R/H 37.5

Side Panel Sheet Metal Repairs - Side Panel

Removal and Installation

Removal

CAUTION: The side panel must be MIG slot brazed to its reinforcement, which contains DP600, (Dual Phase steel). MIG plug

welds / spot welds, must not be used.

• 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 side panel is replaced in conjunction with:

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:

For additional information, refer to: 

Body and Frame

 (501-26 Body

Repairs - Vehicle Specific Information and Tolerance Checks,

Description and Operation) /

Standard Workshop Practices

 (100-00 General Information,

Description and Operation).

3. Remove the hood.
4. Remove the front fender.
5. Remove the front door.

For additional information, refer to: 

Front Door

 (501-03 Body

Closures, Removal and Installation).

6. Remove the rear door.

For additional information, refer to: 

Rear Door

 (501-03 Body

Closures, Removal and Installation).

7. Remove the headliner.

For additional information, refer to: 

Headliner - Vehicles Without:

Tilting Roof Opening Panel

 (501-05 Interior Trim and

Ornamentation, Removal and Installation) /

Headliner - Vehicles With: Tilting Roof Opening Panel

 (501-05

Interior Trim and Ornamentation, Removal and Installation).

8. Remove the instrument panel.

For additional information, refer to: 

Instrument Panel - TD4 2.2L

Diesel

 (501-12 Instrument Panel and Console, Removal and

Installation).

9. Remove the windshield glass.

For additional information, refer to: 

Windshield Glass

 (501-11

Glass, Frames and Mechanisms, Removal and Installation).

10. Remove the rear quarter glass.

For additional information, refer to: 

Rear Quarter Window Glass

(501-11 Glass, Frames and Mechanisms, Removal and Installation).

11. Remove the rear bumper cover.

For additional information, refer to: 

Rear Bumper Cover

 (501-19

Bumpers, Removal and Installation).

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 sections.
17. Remove the side air curtain module.

For additional information, refer to: 

Side Air Curtain Module

(501-20B Supplemental Restraint System, Removal and

Installation).

18. Remove the front seat.

For additional information, refer to: 

Front Seat

 (501-10 Seating,

Removal and Installation).

19. Remove the floor console.

For additional information, refer to: 

Floor Console

 (501-12

Instrument Panel and Console, Removal and Installation).

20. Remove the RH & LH rocker panel inner trims.
21. Remove the rear seat cushion.

For additional information, refer to: 

Rear Seat Cushion

 (501-10

Seating, Removal and Installation).

22. Remove the rear carpet section.
23. Remove the B-Pillar side impact sensor.

For additional information, refer to: 

B-Pillar Side Impact Sensor

(501-20B Supplemental Restraint System, Removal and

Installation).

24. Remove the front safety belt retractor.

For additional information, refer to: 

Front Safety Belt Retractor

(501-20A Safety Belt System, Removal and Installation).

25. Remove the rear safety belt retractor.

For additional information, refer to: 

Rear Safety Belt Retractor

(501-20A Safety Belt System, Removal and Installation).

26. Release and lay aside the front carpet section.
27. Remove the rear carpet section.
28. Remove the front wheel and tire. LINK
29. Remove the rear wheel and tire.

For additional information, refer to: 

Wheel and Tire

 (204-04

Wheels and Tires, Removal and Installation).

30. Remove the rocker panel outer moulding.
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.

For additional information, refer to: 

Fuel Tank Draining

 (310-00

Fuel System - General Information, General Procedures).

39. RH side: Remove the fuel tank filler pipe.

For additional information, refer to: 

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.

 

 

 

 

 

 

 

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