Front spar (Freelander 2)

Contents: Removal ⇩ Installation ⇩

NOTE: The front spar is serviced as a separate welded panel. This procedure involves installing the long section cut from the service panel, discarding the rear section.

NOTE: The service panel is not fully welded.

NOTE: The cut should be made at least 20mm in front of the laser weld.

Removal

1. When replacing the front side member, the following elements are removed:

Front bumper trim
Front bumper
Hood Latch Panel
Both front wings
Front bumper support
Front side member closing panel
Front reinforcement element of the wing apron panel
Lower wing apron panel

NOTE: It is also necessary to remove the engine and suspension as a single unit.

2. For additional information on this repair procedure, refer to the following sources: For additional information, refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation) / Standard Service Station Techniques (100-00 General Information, Description and Operation).

3. Remove the front side member end panel. For more information, refer to the chapter: Front Side Member End Panel (501-27 Front Sheet Metal Repairs, Removal and Installation).

4. Remove the radiator cooling unit. For additional information, refer to the chapter: Radiator (303-03A Engine Cooling - 3.2L NA - I6, Removal and Installation).

5. Remove the engine and front suspension as a single unit.

6. Release the brake line and set it aside.

7. Left side: Release the battery junction box and place it aside.

8. Left side: Remove the air intake pipe.

9. Left side: Release the brake line on the side member and set it aside.

10. Left side: Remove the anti-lock brake system (ABS) module. For additional information, refer to: Anti-lock Brake System (ABS) Module (206-09A Anti-lock Brake System, Removal and Installation).

11. Right side: Remove the windshield washer reservoir. For more information, refer to the chapter: Windshield washer reservoir (501-16 Windscreen wipers and washers, Removal and installation).

12. Right side: Remove the engine support bracket. For more information, refer to the chapter: Right Engine Support (303-01B Engine - 2.2L Duratorq - Td4, Removal and Installation).

13. Right side: Remove the brake lines on the wing apron.

14. Right side: Remove the A/C line from the fender liner.

15. Remove and set aside the insulating material located on the partition.

16. Release the wiring harness and set it aside.

17. Mill out the contact welding areas.

18. Cut the old panel at the location shown. The cut should be at least 20mm in front of the laser weld.

The original text can be found at: lrman.ru

19. Separate the connections and remove the old panel.

Installation

1. Cut a new section from the service panel.

2. Prepare a new panel in the areas shown where it is not fully welded and MIG weld.

3. Prepare the mating surfaces of the old and new panels.

4. Drill holes in the new panel in preparation for MIG welding.

5. Position the new panel in the desired location and secure it in place. Check the alignment. If it is correct, proceed to the next step. If not, make the necessary adjustments and recheck before continuing.

6. After fixing the panels: