Frelander 2. Manual — part 649

41. Saw cut the old panel at the A-Pillar and rear quarter panel, using

the new panel for reference, ensuring that the new panel overlaps

the panel remaining on the vehicle.

42. Saw cut the old panel at the B-Pillar, as illustrated, observe the

measurements to allow access to the B-Pillar reinforcement.

43. Mill

out

the

spot

welds.

44. Separate the joints and remove the old panel, also releasing 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

alignment, if correct, proceed to next step, if not, rectify and

recheck before proceeding.

2. Saw cut the new and old panels at the A-Pillar and rear quarter

panel, ensuring that the new panel overlaps the panel remaining

on the vehicle.

3. Saw cut through the new and old panels at the 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. Drill holes in the new panel ready for MIG plug welding.

7. Prepare the old and new panel joint surfaces.
8. If necessary, renew the NVH element/s.
9. Apply sealer adhesive to the NVH element at the A-Pillar.

10. Apply sealer adhesive to the NVH element at the B-Pillar.

11. Apply sealer adhesive to the NVH elements at the quarter panel.

12. Apply adhesive to the A-Pillar as illustrated.

13. Apply adhesive to the quarter panel as illustrated.

14. Offer up the new panel and clamp into position.
15. Tack weld the butt joints.