Frelander 2. Manual — part 641
2. Drill holes in the new panel ready for MIG plug welding.
3. Offer up the new panel and clamp into position. Check
alignment, if correct, proceed to next step, if not, rectify and
recheck before proceeding.
4. Spot weld.
5. MIG Plug weld.
6. Install weld studs.
7. Dress all welded joints.
8. The installation of associated panels and mechanical
components is the reverse of removal.
Front End Sheet Metal Repairs - Fender Apron Panel Reinforcement
Removal and Installation
Removal
• NOTE: The fender apron panel reinforcement has to be unpicked from the fender apron panel service panel, it is not
available separately.
• NOTE: The RH panel is serviced less its weld studs
1. The fender apron panel reinforcement is replaced in
conjunction with:
Front bumper cover
Hood latch panel
Both front fenders
Fender apron upper panel
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 fender apron upper panel.
For additional information, refer to:
Fender Apron Upper Panel
(501-27 Front End Sheet Metal Repairs, Removal and
Installation).
4. Remove the front shock absorber.
For additional information, refer to:
Front Shock Absorber
(204-01 Front Suspension, Removal and Installation).
5. LH Side: Remove the engine support insulator.
For additional information, refer to:
Engine Upper Support
Insulator
(303-01B Engine - TD4 2.2L Diesel, Removal and
Installation).
6. LH Side: Remove the battery tray.
For additional information, refer to:
Battery Tray
(414-01
Battery, Mounting and Cables, Removal and Installation).
7. LH Side: Remove the air intake pipe.
8. LH Side: Release the battery junction box and position aside.
9. RH Side: Remove the windshield washer reservoir.
For additional information, refer to:
Windshield Washer
Reservoir
(501-16 Wipers and Washers, Removal and
Installation).
10. RH Side: Remove the engine mounting bracket.
For additional information, refer to:
Engine Mount RH
(303-01B
Engine - TD4 2.2L Diesel, Removal and Installation).
11. RH Side: Release the coolant expansion tank and lay it
aside.
12. RH Side: Evacuate the A/C system.
For additional information, refer to:
Air Conditioning (A/C)
System Recovery, Evacuation and Charging
(412-00 Climate
Control System - General Information, General Procedures).
13. RH Side: Remove the fender apron A/C pipes.
14. RH Side: Release and lay aside the insulating material at the
bulkhead.
15. Release and lay aside the wiring harness.
16. Mill out the spot welds.
17. Separate the joints and remove the old panel.
Installation
1. Prepare the old and new panel joint surfaces.
2. Drill holes in the new panel ready for MIG plug welding.
3. Offer up the new panel and clamp into position. Check
alignment, if correct, proceed to next step, if not, rectify and
recheck before proceeding.
4. Spot weld.
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