Frelander 2. Manual — part 638
Front End Sheet Metal Repairs - Front Side Member
Removal and Installation
• NOTE: The front side member is serviced as a separate weld on panel. This procedure is to fit a long section cut from the
service panel, discarding the rear part.
• NOTE: The service panel is not fully welded.
• NOTE: The section must be made at least 20mm forward of the laser weld.
1. The front side member is replaced in conjunction with:
Front bumper cover
Front bumper
Hood latch panel
Both front fenders
Front bumper mounting
Front side member closing panel
Fender apron panel front reinforcement
Fender apron lower panel
• NOTE: It is also necessary to remove the engine and suspension as an assembly.
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 front side member closing panel.
For additional information, refer to:
Front Side Member Closing
Panel
(501-27 Front End Sheet Metal Repairs, Removal and
Installation).
4. Remove the radiator cooling pack.
For additional information, refer to:
Radiator
(303-03A Engine
Cooling - I6 3.2L Petrol, Removal and Installation).
5. Remove the engine and front suspension as an assembly.
6. Release and lay aside the brake pipe.
7. LH Side: Release the battery junction box and position aside.
8. LH Side: Remove the air intake pipe.
9. LH Side: Release and lay aside the brake pipe at the side
member.
10. LH Side: Remove the anti-Lock brake system (ABS) Module.
For additional information, refer to:
Anti-Lock Brake System
(ABS) Module
(206-09A Anti-Lock Control, Removal and
Installation).
11. RH Side: Remove the windshield washer reservoir.
For additional information, refer to:
Windshield Washer
Reservoir
(501-16 Wipers and Washers, Removal and
Installation).
12. 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).
13. RH Side: Remove the fender apron brake pipes.
14. RH Side: Remove the fender apron A/C pipe.
15. Release and lay aside the insulating material at the
bulkhead.
16. Release and lay aside the wiring harness.
17. Mill out the spot welds.
18. Saw cut the old panel at the point illustrated. The cut
should be made at least 20mm forward of the laser weld.
19. Separate the joints and remove the old panel.
Installation
1. Saw cut the new section from the service panel.
2. Prepare and MIG plug weld the new panel in the areas
illustrated, where it is not fully welded.
3. Prepare the old and new panel joint surfaces.
4. Drill holes in the new panel ready for MIG plug welding.
5. Offer up the new panel and clamp into position. Check
alignment, if correct, proceed to next step, if not, rectify and
recheck before proceeding.
6. With panels clamped into position:
1. Tack weld the butt joint.
2. MIG plug weld.
7. Dress the tack welds.
8. MIG weld the butt joint.
9. Dress all welded joints.
10. The installation of associated panels and mechanical
components is the reverse of removal.
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