A-pillar outer panel (Freelander 2)

Contents: Removal ⇩ Installation ⇩

CAUTION: The outer panel of the "A" pillar must be MIG brazed to the reinforcement, which is made of DP600 steel (dual phase steel). MIG welding/spot welding must not be used.

NOTE: The A-pillar outer panel is serviced as a separate weld-on panel. The wing support bracket is serviced separately.

NOTE: There are NVH components attached inside this panel, they are not serviceable on the new panel. If damaged, new component(s) will be required.

Removal

1. In combination with the outer panel of the "A" pillar, the following is replaced:

Front bumper trim
Hood
Front wing
Front door
Instrument panel
Windshield
Ceiling upholstery

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

3. Remove the hood.

4. Remove the front fender.

5. Remove the front door. For more information, refer to the chapter: Front Door (501-03 Lockable Body Parts, Removal and Installation).

6. Remove the headlining. For more information, refer to the chapter: Upper trim - Vehicles not equipped with: Tilting sunroof (501-05 Interior trim, Removal and Installation) / Upper trim - Vehicles equipped with: Tilting sunroof (501-05 Interior trim, Removal and Installation).

7. Remove the instrument panel. For more information, refer to the chapter: Control panel - 2.2L Duratorq - Td4 (501-12 Instrument panel and console, Removal and installation).

8. Remove the windshield. For more information, refer to the chapter: Windshield (501-11 Glass, Frames and Mechanisms, Removal and Installation).

9. Remove the upper and lower door hinges from the pillar, unscrew the 4 bolts.

10. Remove the interior trim of the lower trim panel.

11. Remove the side curtain airbag module. For additional information, refer to: Overhead Side Airbag Module (501-20B Supplemental Restraint System, Removal and Installation).

12. Remove the front wheel and tire assembly. For more information, refer to the chapter: Wheel and tire (204-04 Wheels and tires, Removal and installation).

13. Remove the lower trim panel outer molding.

14. Release and position aside the front carpet section.

15. Remove the rear carpet section.

16. Remove the roof molding, front and rear sections.

17. Release and position aside the wiring harnesses running along the inside of the A-pillar and the inside of the lower trim panel.

18. Remove and place aside the insulation material on the interior partition.

19. Remove the wing support bracket:

Rout 3 spot welds. If the fixture is not being reused, the top spot weld does not need to be removed.
Separate the mount from the "A" pillar.
Keep the mount if it will be reused, if not, discard it.

Keep the mount if it will be reused, if not, discard it.

20. Cut the old panel at the points shown, using the new panel as a reference, making sure the new panel overlaps the panel remaining on the car.

21. Mill out the weld spots.

22. Separate the connections and remove the old panel, also disconnect the NVH element.

Installation

1. Place the new panel, align it and clamp it in place, overlapping the old panel remaining on the car. Cut through the new and old panels at the points where the MIG butt joints are to be made.

2. Remove the new panel and the remains of the old one.

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

4. Cut holes in the new panel for MIG welding.

NOTE: Holes should be made for MIG brazing at the intervals shown in the illustration. Where this is not possible due to recesses in the panel, a hole should be made at the original weld location.

NOTE: Holes should be made for MIG brazing at the intervals shown in the illustration. Where this…

5. Apply the new panel and fix it in place. Check the alignment, if correct, proceed to the next step, if not, correct and check again before proceeding to the next step.

6. Remove the new panel.

7. Apply glue to the areas shown.