Removing and installing the side panel (Freelander 2)

CAUTION: The side panel must be MIG-soldered to your amplifier, which includes the DP600 (duplex steel). MIG welding / spot welding must not be used.

NOTE: The side panel is serviced as a separate welded panel, serviced without the wing support bracket, which is serviced separately.

NOTE: NVH elements are attached inside this panel, they are not serviceable on the new panel. If damaged, a new item will be required (s).

Removing

1. In combination with the sidebar, replaces:

front bumper cover
Front fender
Hood
Front door
Backdoor
Rear side panel glass
Dashboard
Windshield
headlining
rear bumper cover

2. For more information regarding this repair procedure, see: For more information, refer to the chapter: Body and frame (501-26 Body Repairs - Vehicle Special Information and Approval Checks, Description and Operation) / Standard techniques used at the service station (100-00 General information, Description and principle of operation).

3. Remove the hood.

4. Remove the front fender.

5. Remove the front door. For more information, see chapter: Front door (501-03 Lockable body elements, Removal and installation).

6. Remove the back door. For more information, see chapter: Tailgate (501-03 Lockable body elements, Removal and installation).

7. Remove an upholstery of a ceiling. For more information, see chapter: Top trim - Vehicle not included: Tilting sunroof (501-05 Interior trim, Removal and installation) / Upper Trim - Included with the vehicle: Sunroof with tilting roof (501-05 Interior trim, Removal and installation).

8. Remove the instrument panel. For more information, please refer to the chapter: Control panel - 2.2L Duratorq - Td4 (501-12 Instrument panel and console, Removal and installation).

9. Remove the windshield. For more information, see the chapter: Windshield (501-11 Glass, frames and mechanisms, Removal and installation).

10. Remove glass of a back lateral window. For more information, refer to the chapter: Rear Side Window Glass (501-11 Glass, frames and mechanisms, Removal and installation).

11. Remove facing of a back bumper. For more information, see chapter: Rear bumper cover (501-19 Bumpers, Removal and installation).

12. Remove the top and bottom door hinges from the pillar "A", remove 4 bolts.

13. Remove the upper and lower door hinges from the pillar "IN", remove 4 bolts.

14. Remove the latch of the front door lock from the pillar "IN".

15. Remove the latch of the rear door lock from the pillar "WITH".

16. Remove the roof molding, front and rear sections.

17. Remove the side curtain airbag module. For more information, refer to the chapter: Curtain side airbag module (501-20B Secondary restraint system, Removal and installation).

18. Remove the front seat. For more information, see chapter: Front seat (501-10 Seat, Removal and installation).

19. Remove the floor console. For more information, see the chapter: Floor Console (501-12 Instrument panel and console, Removal and installation).

20. Remove the interior trim of the right and left bottom trim panels.

21. Remove the rear seat cushion. For more information, see chapter: Rear seat cushion (501-10 Seat, Removal and installation).

22. Remove the rear carpet section.

23. Remove the side impact sensor from the rack "IN". For more information, refer to the chapter: Strut Side Impact Sensor (501-20B Secondary restraint system, Removal and installation).

24. Remove the front seat belt retractor. For more information, see chapter: Front seat belt retractor (501-20A Seat belt system, Removal and installation).

25. Remove the rear seat belt retractor. For more information, see chapter: Rear seat belt retractor (501-20A Seat belt system, Removal and installation).

26. Loosen and set aside the front carpet section.

27. Remove the rear carpet section.

28. Remove the front wheel and tire assembly. COMPOUND

29. Remove the rear wheel and tire assembly. For more information, see the chapter: Wheel and tire (204-04 Wheels and tires, Removal and installation).

30. Remove the lower trim panel outer molding.

31. Remove the tailgate opening seal.

32. Remove the exhaust grate.

33. Loosen and place aside the insulating material on the inner baffle.

34. Loosen and lay aside the insulation material of the inner rear side panel.

35. Loosen and lay aside rack wiring harnesses "A", racks "IN" and bottom trim panels.

36. Loosen and lay aside the electrical harness along the inner rear side panel and rear panel.

37. Loosen and lay aside the insulation material of the inner rear side panel.

38. Right side: Drain the fuel from the fuel tank. For more information, see the chapter: Emptying the fuel tank (310-00 Fuel supply system - General information, General procedures).

39. Right side: Remove the fuel tank filler pipe. For more information, refer to the chapter: Fuel tank filler pipe (310-01A Fuel tank and fuel lines - 3.2L NA - I6, Removal and installation).

40. Remove the wing support bracket:

Mill 3 spot welds. If the fastener is not reused, the top weld point does not need to be removed.
Separate the rack mount "A".
Save the mount if it will be reused, if not, discard it.

41. Saw off the old panel at the counter "A" and rear side panel, using the new panel as a guide, make sure the new panel overlaps the panel remaining on the vehicle.

42. Saw off the old panel at the rack "IN", as shown in the figure, observe the dimensions to access the rack amplifier "IN".

43. Mill out the weld points.

44. Separate the connections and remove the old panel, also disconnect the NVH elements.

Installation

1. Attach the new panel, align it and lock it in place, overlapping the old panel remaining on the vehicle. Check the reconciliation, if correct, go to the next step, if not, correct and check again before proceeding to the next step.

2. Saw off the new and old panels at the rack "A" and rear side panel, make sure the new panel will overlap with the panel remaining on the vehicle.

3. Saw off the new and old panels at the rack "B", where MIG butt joints are to be made.

4. Remove the new panel and the remains of the old one.

5. Cut holes in the new MIG brazing panel.

NOTE: The holes for MIG brazing must be made according to the gaps shown in the illustration. Where this is not possible due to recesses in the panel, the hole should be made in place of the original spot weld.

6. Drill holes in the new panel for electric MIG welding.

7. Prepare the connecting surfaces of the old and new panels.

8. Replace NVH element (s) if necessary.

9. Apply sealing adhesive to the NVH element of the rack "A".