Frelander 2. Manual — part 635
Section
Description
Gap
Profile
H-H
Fender to front door
5.0 ±1.0
0.7 ±1.0
J-J
Front door to A-Pillar
4.5 ±1.0
-2.5 ±1.2
K-K
Front door finisher to door
0.0 +1.0 -0.0
-2.0 ±1.0
L-L
Front door to rear door
5.0 ±1.0
0.8 ±1.0
M-M
Front door to rear door
5.0 ±1.0
1.0 ±1.0
Section
Description
Gap
Profile
N-N
Rear door finisher to door
0.0 +1.0 -0.0
-2.0 ±1.0
O-O
Rear door to side panel
4.5 ±1.0
-2.5 ±1.2
P-P
Rear door to side panel
4.5 ±1.0
1.0 ±1.0
Q-Q
Rear door to side panel
5.0 ±1.0
0.5 ±0.5
R-R
Side panel to bumper cover
2.0 +1.0 -0.0
1.5 ±1.0
S-S
Side panel to rear lamp
3.0 ±1.5
1.0 ±1.2
Section
Description
Gap
Profile
T-T
Rear lamp to bumper cover
3.0 ±2.0
N/A
U-U
Rear lamp to liftgate
5.0 ±1.5
3.0 ±1.3
V-V
D-Pillar trim panel to liftgate glass
5.0 ±2.0
2.5 ±1.3
W -W
Side panel to liftgate
5.0 ±1.5
2.0 ±1.5
X-X
Liftgate to bumper cover
6.0 ±2.7
N/A
Front End Sheet Metal Repairs - Front End Sheet Metal
Description and Operation
Front end service panels
Item
Description
1
Hood latch panel
2
Fender apron upper panel
3
Fender apron panel front extension
4
Fender apron panel reinforcement
5
Suspension top mount
6
Fender apron panel
7
Front side member and suspension top mount assembly
8
Front side member closing panel
9
Front side member section
10
Fender apron lower panel
11
Front side member
12
Fender apron panel front reinforcement
13
Front bumper mounting
14
Front bumper
Time schedules, front 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 times
Panel Description
Times
Hood
5.6
Front bumper cover
5.5
Front fender
5.5
Hood latch panel
6.2
Engine and Suspension assembly remove and install
8.5
Instrument panel remove and install
6.2
Combination panel replacement times
Combination panel times
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