Frelander 2. Manual — part 640
11. Saw cut the old panel at the point illustrated.
12. Separate the joints and remove the old panel.
Installation
1. Saw cut the new section from the service panel, ensure the
cut is made to align with the cut in the old panel.
2. Prepare the old and new panel joint surfaces.
3. Drill holes in the new panel ready for MIG plug welding.
4. Offer up the new panel and clamp into position. Check
alignment, if correct, proceed to next step, if not, rectify and
recheck before proceeding.
5. With panels clamped into position:
1. Tack weld the butt joint.
2. MIG plug weld.
6. Dress the tack welds.
7. MIG weld the butt joint.
8. Dress all welded joints.
9. The installation of associated panels and mechanical
components is the reverse of removal.
Front End Sheet Metal Repairs - Fender Apron Panel
Removal and Installation
Removal
• NOTE: The fender apron panel is serviced as a separate weld-on panel. It is an assembly of the fender apron panel
reinforcement, fender apron lower panel and fender apron panel front extension.
• NOTE: The panel is serviced less its weld studs
1. The fender apron panel 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. LH Side: Remove the air cleaner.
For additional information, refer to:
Air Cleaner
(303-12A
Intake Air Distribution and Filtering - I6 3.2L Petrol, Removal
and Installation).
5. LH Side: Remove the air intake pipe.
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 engine lower support insulator.
For additional information, refer to:
Engine Lower Support
Insulator
(303-01A Engine - I6 3.2L Petrol, Removal and
Installation).
8. LH Side: Release the battery junction box and position aside.
9. RH Side: Drain the cooling system.
For additional information, refer to:
Cooling System Draining,
Filling and Bleeding
(303-03A Engine Cooling - I6 3.2L Petrol,
General Procedures).
10. 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).
11. RH Side: Remove the power steering reservoir.
For additional information, refer to:
Power Steering Fluid
Reservoir
(211-02 Power Steering, Removal and Installation).
12. RH Side: Release the coolant expansion tank and position
aside.
13. RH Side: Remove the engine mounting bracket.
For additional information, refer to:
Engine Mount RH
(303-01A
Engine - I6 3.2L Petrol, Removal and Installation).
14. RH Side: Remove the windshield washer reservoir.
For additional information, refer to:
Windshield Washer
Reservoir
(501-16 Wipers and Washers, Removal and
Installation).
15. RH Side: Remove the fender apron A/C pipes.
16. Remove the shock absorber and spring assembly.
For additional information, refer to:
Shock Absorber and Spring
Assembly
(204-01 Front Suspension, Removal and
Installation).
17. Release and lay aside the wiring harness.
18. Use a belt sander to remove 5 x spot welds.
19. Mill out the remaining spot welds.
20. Separate the joints and remove the old panel.
Installation
1. Prepare the old and new panel joint surfaces.
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