Contents: Removal ⇩ Installation ⇩
Removal
All cars
NOTE: This procedure requires removal of the body from the body subframe. This procedure can only be performed on a 2-post lift.
1. Open the trunk door.
2. Disconnect the ground cable from the battery. For more information, refer to Specification.
3.
CAUTION: Never work on or under a vehicle that is supported solely by a jack. Always support the vehicle securely.
Raise the vehicle with a jack and install supports.
Cars with manual transmission.
4. Remove the upper floor console panel. For more information, refer to Upper Floor Console Panel (76.25.11)
5. Disconnect the gear shift lever support bracket.
- Remove the soundproofing pad.
- Release the protective cover.
- Remove two bolts.
All cars
6. Remove the wheels and tires.
7. Drain the coolant from the cooling system. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (10/26/01)
8. Drain the refrigerant from the air conditioning (A/C) system. For more information, refer to Refrigerant Recovery, Evacuation and Charging of the Air Conditioning (A/C) System (82.30.02)
9. Remove the air cleaner assembly. For more information, refer to Air Cleaner (10/19/01)
Cars produced since 01/2007
10. Disconnect the engine coolant temperature (ECT) sensor connector.
- Release the clamp.
All cars
11. Remove the 4WD control module. For more information, refer to 4WD Control Module (41.30.01)
12. Disconnect the positive cable from the battery.
- Remove the BJB cover.
- Unscrew the nut.
- Loosen the sealing sleeve.
13. Remove the side wall of the battery compartment.
- Release the positive battery cable and grommet.
- Release the 4 clamps.
14. Release the heater pipes.
- Remove the screw.
15. Remove the battery tray.
- Unscrew the three nuts.
16. Disconnect the heater supply and return hoses.
- Release the 2 clamps and disconnect the hoses.
17. Remove the additional battery tray. For more information, refer to Additional Battery Shelf (76.10.31)
18. Loosen and disconnect the 2 engine wiring harness electrical connectors.
19. Loosen and disconnect the 2 transmission wiring harness electrical connectors.
20. Release the wiring harness cassettes on the engine and gearbox and place them to the side.
- Release the two clamps.
21. Disconnect the glow plug electrical connectors.
- Release the glow plug wiring harness.
22.
CAUTION: Plug all openings. Install new plugs.
Disconnect the high and low pressure air conditioner lines.
- Remove two bolts.
- Remove and discard the 2 O-rings.
23. Disconnect the electrical connector of the low pressure sensor of the air conditioner.
- Release the wiring harness from the mount.
24.
CAUTION: Plug all openings. Install new plugs.
- Disconnect the brake booster vacuum hose.
25.
CAUTION: Do not turn the steering wheel if the lower steering column shaft is disconnected, as this may damage the coil spring and the switches located on the steering wheel.
CAUTION: Make sure the wheels are in the straight-ahead position.
NOTE: Mark the installation position.
Remove the lower steering column shaft.
- Remove and discard the upper bolt of the lower steering column shaft.
26. Remove the mudguards from both front wings. For more information, refer to Mudguard (76.10.48)
27. Remove both lower fender moldings.
- Release the two clamps.
- Repeat the above procedure on the other side of the vehicle.
28. Remove the hood latch panel. For more information, refer to Hood Latch Panel (76.16.22)
Cars produced since 01/2007
29. Left side behind the front headlight: Disconnect the frame wiring harness electrical connector.
30. Left side behind the front panel: Disconnect the 2 electrical connectors from the frame wiring harness.
31. Left side behind headlight: Release 2 clips on the inside of the fender.
All cars
32. Disconnect the fuel-fired auxiliary heater's cooling inlet and outlet hoses.
- Release the two clamps.
33. Disconnect the filler neck of the windshield washer reservoir.
34. Disconnect the two hoses from the expansion tank.
- Release the two clamps.
35. Remove the expansion tank.
- Remove two bolts.
- Disconnect the electrical connectors.
36. Disconnect the cooling fan electrical connector.
37. Disconnect the positive cable from the battery.
- Unscrew the nut.
- Disconnect the positive cable from the battery.
38. Disconnect the fuel line from the fuel fired heater preheater.
39. Disconnect the three electrical connectors from the washer reservoir.
40.
NOTE: Mark the installation position.
Disconnect the two hoses from the washer pump.
41. Left front side: Release the ABS sensor wire.
- Release the two clamps.
- Disconnect the electrical connectors.
- Release from four clamps.
43. Left front side: Disconnect the 2 air ducts.
- Release 5 clamps.
44. Left front side: Disconnect the ground cables from the body subframe.
- Unscrew the nut.
- Disconnect the 2 ground wires.
45.
CAUTION: Before disconnecting or removing components, clean areas around hinges and joints. Insert plugs into exposed joints to prevent dirt from entering.
Left front side: Remove the brake line.
- Place absorbent cloth to absorb spilled fuel.
- Disconnect the nipple connection.
- Remove the clamp.
Cars manufactured before 01/2007
46. Disconnect the 3 electrical connectors from the frame wiring harness.
- Unscrew the nut.
All cars
47. Right Front: Disconnect the air suspension line from the wiring harness clamp.
48. Right front: Release the ABS sensor wire.
- Release the two clamps.
- Disconnect the electrical connectors.
- Unscrew the nut.
50.
CAUTION: Before disconnecting or removing components, clean areas around hinges and joints. Insert plugs into exposed joints to prevent dirt from entering.
Right front: Remove the brake line.
- Place absorbent cloth to absorb spilled fuel.
- Disconnect the nipple connection.
- Remove the clamp.
51. Disconnect the ambient air temperature sensor electrical connector.
- Release the clamp.
Cars manufactured before 01/2007
52. Disconnect the 2 electrical connectors from the frame wiring harness.
- Release the two clamps.
All cars
53. Remove the right rear quarter panel molding. For more information, refer to Rear Quarter Panel Molding (76.43.55)
54. Remove the right rear fender splash guard.
- Remove five screws.
- Remove the retaining ring.
- Disconnect the electrical connectors.
- Repeat the above procedure on the other side of the vehicle.
55. Remove the rear bumper cover. For more information, refer to Rear Bumper Cover (76.22.74)
56. Clear the fuel filler neck.
- Open the filler neck and remove the cap.
- Remove the bolt.
57.
CAUTION: Before disconnecting or removing components, clean areas around hinges and joints. Insert plugs into exposed joints to prevent dirt from entering.
Right rear: Remove the brake line.
- Place absorbent cloth to absorb spilled fuel.
- Disconnect the nipple connection.
- Remove the clamp.
58. Left Rear: Disconnect the 2 electrical connectors from the frame wiring harness.
59.
CAUTION: Before disconnecting or removing components, clean areas around hinges and joints. Insert plugs into exposed joints to prevent dirt from entering.
Left rear: Remove the brake line.
- Place absorbent cloth to absorb spilled fuel.
- Disconnect the nipple connection.
- Remove the clamp.
60.
CAUTION: Before disconnecting or removing components, clean areas around hinges and joints. Insert plugs into exposed joints to prevent dirt from entering.
Left Rear: Disconnect the air suspension air compressor inlet line.
61.
CAUTION: Mark the installation position of the seal.
Disconnect the parking brake cable emergency release cable.
62. Remove the gearbox protection.
- Remove six bolts.
Cars with automatic transmission
63. Remove the gearbox heat shield.
- Remove four bolts.
64. Release the selector lever cable.
- After securing the clamping sleeve with an additional key, loosen the lock nut.
- Press the lock and release the cable.
All cars
65. Remove the body support mounting bolts.
- Remove 10 spacer washers.
66. Temporarily install the wheels and tires.
- Tighten the wheel nuts.
- Lower the car onto the lift.
CAUTION: Never work on or under a vehicle that is supported solely by a jack. Always support the vehicle securely.
CAUTION: To prevent instability of the body when lifting it from the solid frame, install tie-down straps to secure the vehicle.
NOTE: Mark the installation position of the body supports.
NOTE: The body supports are marked with different colors.
With the help of an assistant, lift and support the body.
- Remove 10 body supports.
- With the help of an assistant, lift and support the body.
Installation
All cars
1.
CAUTION: Use new bolts.
CAUTION: Make sure all components are free and will not become caught when lowering the body onto the subframe.
With the help of an assistant, install the body on the subframe.
- Install the body supports.
- With outside help, align the body supports with the subframe supports.
- Screw in the bolts, but do not tighten them completely yet.
3.
CAUTION: Never work on or under a vehicle that is supported solely by a jack. Always support the vehicle securely.
Raise the vehicle with a jack and install supports.
- Raise the vehicle with supports installed under the subframe.
5. Remove the wheels and tires.
Cars with automatic transmission
6. Connect the gear selector cable.
All cars
7. Secure the parking brake emergency release cable.
- Clean the contact surfaces of the elements.
NOTE: Remove and discard plugs.
Left Rear: Connect the air suspension air compressor inlet line.
- Clean the contact surfaces of the elements.
- Clean the contact surfaces of the elements.
- Install the brake line.
- Replace the clamp.
- Tighten the brake pipe union to 16 Nm.
11. Right rear: Connect the brake line.
- Clean the contact surfaces of the elements.
- Install the brake line.
- Replace the clamp.
- Tighten the brake pipe union to 16 Nm.
- Tighten the bolt (tightening torque 10 Nm).
14. Install the rear bumper cover. For more information, refer to Rear Bumper Cover (76.22.74)
15. Install the right rear quarter panel molding. For more information, refer to Rear Quarter Panel Molding (76.43.55)
Cars manufactured before 01/2007
16. Connect the 3 electrical connectors to the frame wiring harness.
- Secure the three clamps.
17. Left front side: Connect the brake line.
- Clean the contact surfaces of the elements.
- Install the brake line.
- Secure the clamp.
- Tighten the brake pipe union to 16 Nm.
- Connect the ground cables.
- Tighten the nut (tightening torque 25 Nm).
20. Left front side: Connect the brake pad wear sensor electrical connector.
- Secure the fasteners.
- Connect the electrical connector.
- Secure the fasteners.
23.
NOTE: Reinstall parts to their original positions.
Connect the washer pump hoses.
24. Connect the electrical connectors of the washer reservoir.
25. Right Front: Secure the subframe wiring harnesses.
- Secure with 2 clamps.
- Clean the contact surfaces of the elements.
- Install the brake line.
- Secure the clamp.
- Tighten the brake pipe union to 16 Nm.
- Connect the electrical connector.
- Secure with clamps.
29. Right Front: Connect the engine ground wire to the body.
- Tighten the nut (tightening torque 25 Nm).
- Connect the electrical connector.
- Secure the clamp.
31. Connect the 2 electrical connectors to the frame wiring harness.
- Secure the two clamps.
32. Connect the fuel-fired auxiliary heater cooling hoses.
- Secure the clamps.
34. Install the hood latch panel. For more information, refer to Hood Latch Panel (76.16.22)
Cars produced since 01/2007
35. Route the frame wiring harness through the front fender.
36. Left side behind the front headlight: Connect the frame wiring harness electrical connector.
37. Left side behind the front panel: Connect the 2 electrical connectors to the frame wiring harness.
38. Left side behind headlight: Secure 2 clips to the inside of the fender.
All cars
39. Install the expansion tank of the cooling system.
- Connect the electrical connector.
- Tighten the bolts to a torque of 10 Nm.
- Secure with clamps.
42. Secure the power steering fluid reservoir.
- Position and secure to support bracket.
44. Install the mudguards on both front fenders. For more information, refer to Fender Mudguard (76.10.48)
45. Install the lower fender molding.
- Engage 2 clamps.
- Repeat the above procedure on the other side of the vehicle.
NOTE: Remove and discard plugs.
Connect the high and low pressure air conditioner pipes.
- Clean the contact surfaces of the elements.
- Install new O-rings.
- Secure the wire harness clamp.
- Secure the glow plug wiring harness.
Cars produced since 01/2007
50. Connect the engine coolant temperature (ECT) sensor electrical connector.
- Secure the clamp.
51. Secure the engine and gearbox wiring harnesses and cassettes.
52. Connect the two electrical connectors of the engine wiring harness.
53. Connect the two electrical connectors of the transmission wiring harness.
54. Install the engine and gearbox wiring harness cassettes.
55. Install the additional battery tray. For more information, refer to Additional Battery Shelf (76.10.31)
56.
NOTE: Make sure the wheels are in the straight-ahead position.
Attach the lower steering column shaft.
- Clean the contact surfaces of the elements.
- Screw in a new locking bolt and tighten to 25 Nm.
- Secure with clamps.
NOTE: Remove and discard plugs.
Connect the brake booster vacuum hose.
59. Install the battery tray.
- Tighten the nuts (tightening torque 12 Nm).
61. Install the battery compartment side wall.
- Secure with clamps.
- Connect the positive battery cable to the BJB.
- Tighten the nut (tightening torque 25 Nm).
- Install the sealing ring.
- Install the BJB cover.
63. Install the floor console top panel. For more information, refer to Floor Console Top Panel (76.25.11)
64. Secure the gear shift lever support bracket.
- Tighten the bolts (tightening torque 25 Nm).
- Secure the protective cover.
- Install soundproofing pad.
65. Install the air cleaner assembly. For more information, refer to Air Cleaner (10/19/01)
66. Connect the battery ground cable. For more information, refer to Specification.
67. Add coolant to the cooling system and bleed air from it. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (10/26/01)
68. Recharge the air conditioner. For more information, refer to Refrigerant Recovery, Evacuation, and Charging of the Air Conditioning (A/C) System (82.30.02)
69. Bleed the brake system. For more information, refer to Bleeding the Brake System (70.25.02)
70. Install the wheels and tires.
- Tighten the nuts (tightening torque 140 Nm).
71. Adjust the selector cable. For more information, refer to Adjusting the Gear Selector Cable (44.30.04)
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