Frelander 2. Manual - part 659

 

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Frelander 2. Manual - part 659

 

 

Item

Description

19

Inner quarter panel and wheelhouse

20

Rear bumper mounting

21

Liftgate

Time schedules, rear 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

Rear bumper cover

5.1

Liftgate

6.9

Rear lamp mounting panel

L/H 8.5

R/H 8.6

Back panel

14.6

Quarter panel

L/H 22.9

R/H 24.1

Headliner remove and install

3.3

Liftgate screen remove and install

1.4

Rear suspension assembly remove and install

4.0

Fuel tank remove and install

2.5

Combination panel replacement times

Combination panel times

Panel Description

Times

Rear bumper cover
Rear bumper
Liftgate
Rear lamp mounting panel
Back panel
Quarter panel
Headliner remove and install
Liftgate screen remove and install
Total Time

L/H 44.3

R/H 45.3

Combination panel times

Panel Description

Times

Rear bumper cover
Rear bumper
Liftgate
Rear lamp mounting panel L/H and R/H
Back panel
Inner back panel assembly
Quarter panel L/H and R/H
Headliner remove and install
Liftgate screen remove and install
Total Time

62.5

Combination panel times

Panel Description

Times

Rear bumper cover
Rear bumper
Liftgate
Back panel
Inner back panel assembly
Quarter panel
Spare wheel well
Rear crossmember
Rear bumper mounting
Rear side member section
Rear side member closing panel
Rear side member upper side extension
Water drain panel section
Inner quarter panel and wheelarch
Headliner remove and install
Liftgate screen remove and install
Fuel tank remove and install
Rear suspension assembly remove and install
Total Time

L/H 69.6

R/H 70.3

Combination panel times

Panel Description

Times

Rear bumper cover
Rear bumper
Liftgate
Back panel
Inner back panel assembly
Quarter panel L/H and R/H
Spare wheel well
Rear crossmember
Rear bumper mounting L/H and R/H
Rear side member section L/H and R/H
Rear side member closing panel L/H and R/H
Rear side member upper side extension L/H and R/H
Water drain panel section L/H and R/H
Inner quarter panel and wheelarch L/H and R/H
Headliner remove and install
Liftgate screen remove and install
Fuel tank remove and install
Rear suspension assembly remove and install
Total Time

95.9

Combination panel times

Panel Description

Times

Rear bumper cover
Rear bumper
Liftgate
Back panel
Inner back panel assembly
Rear lamp mounting panel
Spare wheel well
Rear bumper mounting
Rear side member section
Rear side member closing panel
Rear side member upper side extension
Liftgate screen remove and install
Fuel tank remove and install
Rear suspension assembly remove and install
Total Time

L/H 47.1

R/H 47.1

Combination panel times

Panel Description

Times

Rear bumper cover
Rear bumper
Liftgate
Back panel
Inner back panel assembly
Rear lamp mounting panels L/H and R/H
Spare wheel well
Rear crossmember
Rear bumper mounting L/H and R/H
Liftgate screen remove and install
Fuel tank remove and install
Rear suspension assembly remove and install
Total Time

43.9

Rear End Sheet Metal Repairs - Quarter Panel

Removal and Installation

Removal

CAUTION: The quarter panel must be MIG slot brazed to the rocker panel inner reinforcement, which is DP600, (Dual

Phase steel). MIG plug welds / spot welds must not be used in this area.

• NOTE: The quarter panel is serviced as a separate weld-on panel.

• NOTE: There are NVH elements inside this panel, they are not serviced on the new panel. If damaged, a new element

will be required.

1. The quarter panel is replaced in conjunction with:

Rear bumper cover

Rear door

Quarter glass

Headliner

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 rear bumper cover.

For additional information, refer to: 

Rear Bumper

 (501-19

Bumpers, Removal and Installation).

4. Remove the rear door.

For additional information, refer to: 

Rear Door

 (501-03 Body

Closures, Removal and Installation).

5. Remove the headliner.

For additional information, refer to: 

Headliner - Vehicles

Without: Tilting Roof Opening Panel

 (501-05 Interior Trim and

Ornamentation, Removal and Installation) /

Headliner - Vehicles With: Tilting Roof Opening Panel

 (501-05

Interior Trim and Ornamentation, Removal and Installation).

6. Remove the rear door striker from the C-Pillar.
7. Remove the roof moulding, front and rear sections.
8. Remove the side air curtain module.

For additional information, refer to: 

Side Air Curtain Module

(501-20B Supplemental Restraint System, Removal and

Installation).

9. Remove the rear quarter glass.

For additional information, refer to: 

Rear Quarter Window

Glass

 (501-11 Glass, Frames and Mechanisms, Removal and

Installation).

10. Remove the front seat.

For additional information, refer to: 

Front Seat

 (501-10

Seating, Removal and Installation).

11. Remove the floor console.

For additional information, refer to: 

Floor Console

 (501-12

Instrument Panel and Console, Removal and Installation).

12. Remove the RH & LH rocker panel inner trims.
13. Remove the rear seat cushion.

For additional information, refer to: 

Rear Seat Cushion

 (501-10

Seating, Removal and Installation).

14. Remove the rear carpet section.
15. Remove the rear safety belt retractor.

For additional information, refer to: 

Rear Safety Belt Retractor

(501-20A Safety Belt System, Removal and Installation).

16. Remove the liftgate aperture weatherseal.
17. Remove the forced air extraction grille.
18. Remove the rear wheel and tire.

For additional information, refer to: 

Wheel and Tire

 (204-04

Wheels and Tires, Removal and Installation).

19. Remove the rocker panel outer moulding.
20. Release and lay aside the wiring harness along the inner

quarter panel and back panel.

21. Release and lay aside the insulating material at the inner

quarter panel.

22. RH side: Drain the fuel tank.

For additional information, refer to: 

Fuel Tank Draining

 (310-00

Fuel System - General Information, General Procedures).

23. RH side: Remove the fuel tank filler pipe.

For additional information, refer to: 

Fuel Tank Filler Pipe

(310-01A Fuel Tank and Lines - I6 3.2L Petrol, Removal and

Installation).

24. Saw cut the old panel at the points illustrated, using the

new panel for reference, ensuring that the new panel

overlaps.

25. Mill out the spot welds.

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

the NVH elements and the fuel filler on the RH.

Installation

 

 

 

 

 

 

 

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