Removal and installation of a body of the petrol car (Discovery 3)

Removing

NOTE: This procedure requires the body to be removed from the body subframe. This procedure can only be performed on a 2 post lift.

WARNING: It is forbidden to carry out work on a vehicle supported only by a jack. Be sure to place reliable pores under the car.

Raise and support the vehicle.

2. Remove wheels.

3. Disconnect a wire of weight from the accumulator. For more information refer to Specification.

4. Drain the coolant. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (26.10.01)

5. Unload the refrigerant. For more information, refer to Refrigerant Recovery, Vacuuming and Charging the Air Conditioning System (A/C) (82.30.02)

6. Remove the air filter assembly. For more information refer to Air Filter (19.10.01)

7. Remove TCM. For more information refer to Four Wheel Drive Control Module (4WD) (41.30.01)

8. Remove the right top heat-shielding screen of a motor compartment.

Remove the screw.

9. Disconnect the positive cable from the battery.

Remove the BJB cover.
Loosen the nut.
Remove the sealing sleeve.

10. Remove the side wall of the battery box.

Release four clamps.

11. Remove the protruding section of the side wall of the battery box.

12. Release the battery positive wire bracket.

Remove two nuts.

13. Release and disconnect the two electrical connectors of the engine wiring harness.

14. Release and disconnect two electric sockets on a transmission.

15. Release the bundles of wiring harnesses on the engine and transmission and place them to the side.

Release two clamps.

16. Remove the mudguards of both front fenders. For more information refer to Fender Mudguard (76.10.48)

17. Remove the lower wing molding.

Release two clamps.
Repeat the above procedure on the other side.

18. Remove facing of a forward bumper. For more information refer to Front Bumper Cover (76.22.72)

19. Remove the lower radiator air deflector.

Remove three clamps.

20. Remove the switch of systems of dynamic stabilization in gathering. For more information, refer to Switch for optimizing suspension and handling performance (86.65.11)

21. Release the power steering reservoir from the bracket.

22. Disconnect the filler neck of the windshield washer reservoir

23. Disconnect two hoses from a broad tank.

Release two clamps.

24. Remove the expansion tank.

Disconnect the electrical connector.
Turn out two bolts.

25.

CAUTION: Before you start disconnecting or removing elements, make sure that the area around the contact surfaces and connections is clean and dry. Plug open connections to prevent contamination.

Disconnect the brake booster vacuum hose.

Release the clamp.

26.

CAUTION: Before you start disconnecting or removing elements, make sure that the area around the contact surfaces and connections is clean and dry. Plug open connections to prevent contamination.

Disconnect the A/C compressor low pressure line.

Discard the oil seal.

27.

CAUTION: Plug off all refrigerant lines immediately to prevent dirt and moisture from entering.

Disconnect the A/C condenser high pressure line.

Discard the oil seal.

28. Remove the radiator mounting pins.

Squeeze two clamps.

29. Disconnect the two heater coolant hoses.

Release from two clamps.

30. Disconnect the two coolant hoses from the heater.

Release the clamps.

31. Disconnect the three electrical connectors for the washer reservoir.

32.

NOTE: Mark the installation position.

Disconnect the two hoses from the washer pump.

33. Disconnect the outdoor air temperature sensor wiring harness.

Release the clamp.
Disconnect the electrical connector.

34. Right front: Release the air suspension line from the harness clamp.

35. Right front: Release the ABS sensor wire.

Release two clamps.
Disconnect the electrical connector.

36. Right front: Disconnect the engine ground wire from the body.

Loosen the nut.

37. Right front: Disconnect the two body harness electrical connectors.

Disconnect the two electrical connectors.

38. Right front: Release the body frame wiring harness.

Release two clamps.

39.

CAUTION: Before you start disconnecting or removing elements, make sure that the area around the contact surfaces and connections is clean and dry. Plug open connections to prevent contamination.

Right front: Release the brake line.

Place an absorbent cloth to catch any spilled liquid.
Disconnect the nipple connection.
Remove clamp.

40. Left front side: Release the ABS sensor wire.

Release two clamps.
Disconnect the electrical connector.

41. Left front: Disconnect the brake pad wear sensor electrical connector.

Release from four clips.

42. Left front side: Release the two air ducts.

Release from the five clamps.

43. Left front side: Remove the engine compartment heat shield.

Remove three nuts.

44. Disconnect the lower steering column shaft from the steering column.

Loosen and discard the Torx bolt.

45. Left front side: Disconnect the three electrical connectors of the body wiring harness.

46. Left front side: Release the built-in ground wire on the body subframe.

Loosen the nut.
Release the two earth wires.

47.

CAUTION: Before you start disconnecting or removing elements, make sure that the area around the contact surfaces and connections is clean and dry. Plug open connections to prevent contamination.

Left front side: Release the brake line.

Place an absorbent cloth to catch any spilled liquid.
Disconnect the nipple connection.
Remove clamp.

48. Remove the rear fender moldings. For more information, refer to Rear Side Panel Molding (76.43.55)

49. Remove the mudguard of the right rear fender.

Remove five screws.
Remove the stopper.
Disconnect the electrical connector.
Repeat the above procedure on the other side.

50. Remove facing of a back bumper. For more information refer to Rear Bumper Cover (76.22.74)

51. Remove the fuel tank filler cap. For more information, refer to Fuel Filler Cap Assembly (19.55.04)

52. Release the filler neck of the fuel tank.

Turn out a bolt.

53.

CAUTION: Before you start disconnecting or removing elements, make sure that the area around the contact surfaces and connections is clean and dry. Plug open connections to prevent contamination.

Rear right: Disconnect the brake line.

Place an absorbent cloth to catch any spilled liquid.
Disconnect the nipple connection.
Remove clamp.

54. Rear left: Disconnect the two body harness electrical connectors.

55.

CAUTION: Before you start disconnecting or removing elements, make sure that the area around the contact surfaces and connections is clean and dry. Plug open connections to prevent contamination.

Rear left: Disconnect the brake line.

Place an absorbent cloth to catch any spilled liquid.
Disconnect the nipple connection.
Remove clamp.

56.

CAUTION: Before you start disconnecting or removing elements, make sure that the area around the contact surfaces and connections is clean and dry. Plug open connections to prevent contamination.

Rear left: Disconnect the air suspension air compressor intake line.

Raise the car on a lift.

57.

CAUTION: Mark the installation position of the seal.

Disconnect the parking brake emergency release cable.

58. Remove the lower transmission protection.

Remove six bolts.

59. Remove the transmission heat shield.

Turn out four bolts.

60. Release the gear selection cable.

While holding the clamping sleeve with the second wrench, loosen the locknut.
Press the latch and release the cable.

61. Turn out bolts of fastening of a support of a body.

Remove 10 spacers.

62. Temporarily install the wheels.

Lower the car on the lift.
Screw on the wheel nuts.

63.

NOTE: Mark the installation position of the body supports.

NOTE: Body supports are color coded.

Raise and support the body.

Remove 10 body supports.

Installation

NOTE: Body supports are color coded.

NOTE: Install the elements according to their original position.

Install body mounts.

Clean the mating surfaces of the elements.

CAUTION: Carefully lower the body onto the body frame. Make sure that no elements are pinched. Pay special attention to loose connections and the radiator area.

Install the body on the body frame.

Clean the mating surfaces of the elements.
With assistance, align the body supports with the subframe supports.
Install spacers.
Screw in the bolts, but do not tighten them all the way yet.

3. Remove wheels.

Raise the vehicle using the supports located under the body subframe.

4. Tighten the subframe-to-body bolts to 133 Nm.

5. Connect the gear selection cable.

6. Attach the parking brake emergency release cable.

Clean the mating surfaces of the elements.

7. Left rear: Connect the air suspension air compressor intake line.

Clean the mating surfaces of the elements.
Fasten the clamp.

8. Left rear: Connect the brake line.

Lower the car on the lift.
Clean the mating surfaces of the elements.
Establish the brake pipeline.
Install the clamp.
Tighten the nipple connection of the brake pipeline with a force of 16 Nm.

9. Rear left: Connect the two body harness electrical connectors.

10. Right rear: Connect the brake line.

Clean the mating surfaces of the elements.
Establish the brake pipeline.
Install the clamp.
Tighten the nipple connection of the brake pipeline with a force of 16 Nm.

11. Fix a jellied mouth of a fuel tank.

Tighten the bolt to 10 Nm.

12. Install the latch of the fuel filler cap. For more information, refer to Fuel Filler Cap Assembly (19.55.04)

13. Establish facing of a back bumper. For more information refer to Rear Bumper Cover (76.22.74)

14. Establish mudguards of both back wings.

15. Establish moldings of both back wings. For more information, refer to Rear Side Panel Molding (76.43.55)

16. Left front side: Connect the brake line.

Clean the mating surfaces of the elements.
Establish the brake pipeline.
Fasten the clamp.
Tighten the nipple connection of the brake pipeline with a force of 16 Nm.

17. Left front side: Connect the body subframe ground wire.

Connect ground wires.
Tighten the nut to 25 Nm.

18. Left front side: Mate the three electrical connectors of the body wiring harness.

19.

NOTE: Move steering to position. corresponding to rectilinear motion.

Connect the lower steering column shaft.

Clean the mating surfaces of the elements.
Screw in a new self-locking bolt and tighten it to 25 Nm.

20. Left front: Install the engine room heat shield.

Tighten the nuts to 10 Nm.

21. Left front side: Clamp the air lines.

22. Left front side: Connect the brake pad wear sensor electrical connector.

Fasten with clips.

23. Left front side: Connect the ABS sensor wire.

Connect the electrical connector.
Fasten with clips.

24. Right front: Mate the two electrical connectors of the body harness.

25. Right front: Attach body frame wiring harness.

Secure with two clips.

26. Right front: Connect the brake line.

Clean the mating surfaces of the elements.
Establish the brake pipeline.
Fasten the clamp.
Tighten the nipple connection of the brake pipeline with a force of 16 Nm.

27. Right front: Connect the engine ground bar to the body.

Tighten the nut to 25 Nm.

28. Right front: Connect the ABS sensor wire.

Connect the electrical connector.
Lock the clamps.

29. Right front: Clamp the air suspension line to the harness clamp.

30. Connect the outdoor air temperature sensor harness.

Connect the electrical connector.
Fasten the clamp.

31.

NOTE: Install the elements according to their original position.

Connect the washer pump hoses.

32. Dock the electrical connectors of the washer reservoir.

33.

CAUTION: Lubricate new seals with clean compressor oil.

Connect the A/C compressor low pressure line.

Clean the mating surfaces of the elements.
Install a new sealing ring.
Tighten the bolt to 6 Nm.

34.

CAUTION: Lubricate new seals with clean compressor oil.

Connect the A/C condenser high pressure line.

Clean the mating surfaces of the elements.
Install a new sealing ring.
Tighten the bolt to 6 Nm.

35. Connect the brake booster vacuum hose to the intake manifold.

Clean the mating surfaces of the elements.

36. Install the expansion tank of the cooling system.

Connect the electrical connector.
Tighten the bolts to 10 Nm.

37. Attach the hoses to the expansion tank of the cooling system.

Lock the clamps.

38. Establish a jellied mouth of a reservoir of a washer of a windshield.

39. Reinstall the power steering reservoir.

Position and secure on the support bracket.

40. Install the radiator mounting pins.

41. Install the lower radiator air deflector.

Secure with three clips.

42. Establish facing of a forward bumper. For more information refer to Front Bumper Cover (76.22.72)

43. Install mudguards on both front fenders. For more information refer to Fender Mudguard (76.10.48)

44. Install the lower wing molding.

Secure with two fasteners.
Repeat the above procedure on the other side.

45. Attach the engine and transmission harness bundles.

46. Connect the two electrical connectors of the engine wiring harness.

47. Connect the two electrical connectors of the transmission wiring harness.

48. Install the engine and transmission harness bundles.

49. Install TCM. For more information refer to Four Wheel Drive Control Module (4WD) (41.30.01)

50. Install the protruding panel on the side wall of the battery box.

51. Install the side wall of the battery box.

Lock the clamps.

52. Install the upper engine compartment heat shield.

Screw in the screw.

53. Install the positive battery cable.

Connect the positive battery cable to the BJB.
Tighten the nut to 25 Nm.
Install the sealing sleeve.
Install the BJB cover.

54. Connect the coolant hoses to the heater.

Lock the clamps.

55. Attach the heater coolant hoses.

Fasten with clips.

56. Install the air filter assembly. For more information refer to Air Filter (19.10.01)

57. Connect the mass wire to the battery. For more information refer to Specification.

58. Fill the cooling system with coolant and remove air from the systems. For more information, refer to Draining/Filling Coolant and Bleeding the System! cooling (26.10.01)

59. Prime the A/C system. For more information, refer to Refrigerant Recovery, Vacuuming and Charging the Air Conditioning System (A/C) (82.30.02)

60. Remove air from the brake system. For more information, refer to Bleeding the System! brakes (70.25.02)

61. Install the wheels.

62. Establish the switch of system of dynamic stabilization in gathering. For more information, refer to Switch for optimizing suspension and handling performance (86.65.11)

63. Adjust the gear selection cable. For more information, refer to Selector Lever Cable Adjustment (44.30.04)

64. Install the transmission heat shield.