Body and Frame: Service and Repair

Body - Petrol

The Content of this article/image reflects the changes identified in TSB - TECLTB00278.

Removal

NOTE: In this procedure, the body is removed from the integrated body-frame. This procedure can only be performed using a 2-Post ramp.

1. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.

2. Remove the wheels and tires.
3. Disconnect the battery ground cable.
4. Complete coolant drain has been replaced with a coolant top up as only one (1) liter is lost.
For additional information, Service and Repair
5. Recover the A/C refrigerant.
6. Remove the air cleaner assembly.
7. Remove the TCM.
8. Remove the engine compartment RH upper heat shield.
^ Remove the screw.







9. Release the battery positive cable.
^ Remove the BJB cover.
^ Remove the nut.
^ Release the grommet.







10. Remove the battery compartment side wall.
^ Release the 4 clips.

11. Remove the battery compartment side wall extension.







12. Release the battery positive cable bracket.
^ Remove the 2 nuts.







13. Release and disconnect the 2 engine harness electrical connectors.







14. Release and disconnect the 2 transmission harness electrical connectors.







15. Release the engine and transmission harness cassettes, position the harnesses aside.
^ Release the 2 clips.







16. Shields located under the front wheel arches no longer require removal.
17. Remove the fender lower moulding.
^ Release the 2 clips.
^ Repeat the above procedure for the other side.







18. Remove the front bumper cover.
Bumper renew (front and rear) has been replaced with bumper remove / refit for access.
19. Remove the radiator lower air deflector.
^ Remove the 3 clips.







20. Remove the ride and handling optimization switch assembly.
21. Release the power steering fluid reservoir from the retaining bracket.
22. Remove the windshield washer reservoir filler neck.
23. Disconnect the 2 hoses from the coolant expansion tank.
^ Release the 2 clips.







24. Remove the coolant expansion tank.
^ Disconnect the electrical connector.
^ Remove the 2 bolts.







25. CAUTION: Before disconnecting or removing the components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

Disconnect the brake booster vacuum hose.
^ Release the clip.







26. CAUTION: Before disconnecting or removing the components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

Disconnect the A/C compressor low pressure line.
^ Discard the O-ring seal.







27. CAUTION: Immediately cap all refrigerant lines to prevent ingress of dirt and moisture.

Disconnect the A/C condenser high pressure line.
^ Discard the O-ring seal.

28. Remove the radiator securing pegs.
^ Depress the 2 clips.







29. Release the 2 heater coolant hoses.
^ Release from the 2 clips.

30. Disconnect the 2 heater coolant hoses.
^ Release the clips.







31. Disconnect the washer reservoir 3 electrical connectors.

32. NOTE: Note the fitted position.

Disconnect the 2 washer pump hoses.







33. Disconnect the ambient air temperature sensor harness.
^ Release the clip.
^ Disconnect the electrical connector.







34. RH side front: Release the air suspension line from the wiring harness clip.
35. RH side front: Release the ABS sensor lead.
^ Release the 2 clips.
^ Disconnect the electrical connector.

36. RH side front: Disconnect the engine ground cable from the body.
^ Remove the nut.







37. RH side front: Disconnect the 2 body harness electrical connectors.
^ Disconnect the 2 electrical connectors.

38. RH side front: Release the body-frame harness.
^ Release the 2 clips.







39. CAUTION: Before disconnecting or removing the components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

RH side front: Release the brake line.
^ Position an absorbent cloth to collect fluid spillage.
^ Disconnect the line union.
^ Remove the clip.







40. LH side front: Release the ABS sensor lead.
^ Release the 2 clips.
^ Disconnect the electrical connector.

41. LH side front: Disconnect the brake pad wear sensor electrical connector.
^ Release from the 4 clips.







42. LH side front: Release the 2 air lines.
^ Release from the 5 clips.







43. LH side front: Remove the engine compartment heat shield.
^ Remove the 3 nuts.







44. Disconnect the steering column lower shaft from the steering column.
^ Remove and discard the Torx bolt.







45. LH side front: Disconnect the 3 body harness electrical connectors.







46. LH side front: Release the integrated body frame ground cable.
^ Remove the nut.
^ Release the 2 ground cables.







47. CAUTION: Before disconnecting or removing the components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

LH side front: Release the brake line.
^ Position an absorbent cloth to collect fluid spillage.
^ Disconnect the line union.
^ Remove the clip.







48. Remove the rear fender mouldings.
49. Remove the RH rear fender splash shield.
^ Remove the 5 screws.
^ Remove the retainer.
^ Disconnect the electrical connector.
^ Repeat the above procedure for the other side.







50. Remove the rear bumper cover.
Bumper renew (front and rear) has been replaced with bumper remove / refit for access.
51. Remove the fuel filler flap assembly.
52. Release the fuel filler neck.
^ Remove the bolt.







53. CAUTION: Before disconnecting or removing the components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

RH side rear: Disconnect the brake line.
^ Position an absorbent cloth to collect fluid spillage.
^ Disconnect the line union.
^ Remove the clip.







54. LH side rear: Disconnect the 2 body harness electrical connectors.







55. CAUTION: Before disconnecting or removing the components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

LH side rear: Disconnect the brake line.
^ Position an absorbent cloth to collect fluid spillage.
^ Disconnect the line union.
^ Remove the clip.







56. CAUTION: Before disconnecting or removing the components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

LH side rear: Disconnect the suspension air compressor intake line.
^ Raise the vehicle on the lift.







57. CAUTION: Note the fitted position of the seal.

Release the parking brake emergency release cable.







58. Remove the transmission undershield.
^ Remove the 6 bolts.







59. Remove the transmission heat shield.
^ Remove the 4 bolts.







60. Release the selector cable.
^ Using an additional wrench, restrain the clamping bush and loosen the locknut.
^ Compress the latch and release the cable.







61. Remove the body mount retaining bolts.
^ Remove the 10 spacing washers.







62. Temporarily install the road wheels and tires.
^ Lower the vehicle on the lift.
^ Install the wheel nuts.

63. NOTE:
^ Note the fitted position of the body mounts.
^ The body mounts are color coded.

Raise and support the body.
^ Remove the 10 body mounts.







Installation

1. NOTE:
^ The body mounts are color coded.
^ Install the components to their original fitted positions.

Install the body mounts.
^ Clean the component mating faces.

2. CAUTION: Carefully lower the body onto the integrated body frame. Make sure components do not get trapped. Pay particular attention to loose connections and the radiator area.

Install the body to the integrated body frame.
^ Clean the component mating faces.
^ With assistance align the body and integrated body frame mounts.
^ Install the spacing washers.
^ Install the bolts, but do not tighten fully at this stage.

3. Remove the wheels and tires.
^ Raise the vehicle with the supports under the integrated body-frame.

4. Tighten the integrated body-frame to body bolts to 133 Nm (98 lb.ft).
5. Attach the selector cable.
6. Secure the parking brake emergency release cable.
^ Clean the component mating faces.

7. LH side rear: Connect the suspension air compressor intake line.
^ Clean the component mating faces.
^ Secure the clip.

8. LH side rear: Connect the brake line.
^ Lower the vehicle on the lift.
^ Clean the component mating faces.
^ Install the brake tube.
^ Install the clip.
^ Tighten the brake line union to 16 Nm (12 lb.ft).

9. LH side rear: Connect the 2 body harness electrical connectors.
10. RH side rear: Connect the brake line.
^ Clean the component mating faces.
^ Install the brake tube.
^ Install the clip.
^ Tighten the brake line union to 16 Nm (12 lb.ft).

11. Secure the fuel filler neck.
^ Tighten the bolt to 10 Nm (7 lb.ft).

12. Install the fuel filler flap latch assembly.
13. Install the rear bumper cover.
Bumper renew (front and rear) has been replaced with bumper remove / refit for access.
14. Install both rear fender splash shields.
15. Install both rear fender mouldings.
16. LH side front: Connect the brake line.
^ Clean the component mating faces.
^ Install the brake tube.
^ Secure the clip.
^ Tighten the brake line union to 16 Nm (12 lb.ft).

17. LH side front: Connect the integrated body frame ground cable.
^ Connect the ground cables.
^ Tighten the nut to 25 Nm (18 lb.ft).

18. LH side front: Connect the 3 body harness electrical connectors.

19. NOTE: Make sure the steering is in the straight ahead position.

Connect the steering column lower shaft.
^ Clean the component mating faces.
^ Install new patchlock bolt and tighten to 25 Nm (18 lb.ft).

20. LH side front: Install the engine compartment heat shield.
^ Tighten the nuts to 10 Nm (7 lb.ft).

21. LH side front: Secure the air lines to the clips.
22. LH side front: Connect the brake pad wear sensor electrical connector.
^ Secure in the clips.

23. LH side front: Connect the ABS sensor lead.
^ Connect the electrical connector.
^ Secure in the clips.

24. RH side front: Connect the 2 body harness electrical connectors.
25. RH side front: Secure the body-frame harness.
^ Secure with the 2 clips.

26. RH side front: Connect the brake line.
^ Clean the component mating faces.
^ Install the brake tube.
^ Secure the clip.
^ Tighten the brake line union to 16 Nm (12 lb.ft).

27. RH side front: Connect the engine ground strap to the body.
^ Tighten the nut to 25 Nm (18 lb.ft).

28. RH side front: Connect the ABS sensor lead.
^ Connect the electrical connector.
^ Secure the clips.

29. RH side front: Install the air suspension line to the wiring harness clip.
30. Connect the ambient air temperature sensor harness.
^ Connect the electrical connector.
^ Secure the clip.

31. NOTE: Install the components to their original fitted positions.

Connect the washer pump hoses.

32. Connect the washer reservoir electrical connectors.

33. CAUTION: Lubricate the new seals with clean refrigerant oil.

Connect the A/C compressor low pressure line.
^ Clean the component mating faces.
^ Install a new O-ring seal.
^ Tighten the bolt to 6 Nm (4 lb.ft).

34. CAUTION: Lubricate the new seals with clean refrigerant oil.

Connect the A/C condenser high pressure line.
^ Clean the component mating faces.
^ Install a new O-ring seal.
^ Tighten the bolt to 6 Nm (4 lb.ft).

35. Connect the brake booster vacuum hose to the intake manifold.
^ Clean the component mating faces.

36. Install the coolant expansion tank.
^ Connect the electrical connector.
^ Tighten the bolts to 10 Nm (7 lb.ft).

37. Connect the coolant hoses to the expansion tank.
^ Secure the clips.

38. Install the windshield washer reservoir filler neck.
39. Install the power steering fluid reservoir.
^ Position and secure to mounting bracket.

40. Install the radiator securing pegs.
41. Install the radiator lower air deflector.
^ Secure with the 3 clips.

42. Install the front bumper cover.
Bumper renew (front and rear) has been replaced with bumper remove / refit for access.
43. Shields located under the front wheel arches no longer require removal.
44. Install the fender lower moulding.
^ Secure in the 2 clips.
^ Repeat the above procedure for the other side.

45. Align the engine, transmission harness and cassettes.
46. Connect the 2 engine harness electrical connectors.
47. Connect the 2 transmission harness electrical connectors.
48. Install the engine and transmission harness cassettes.
49. Install the TCM.
50. Install the battery compartment side wall extension.
51. Install the battery compartment side wall.
^ Secure the clips.

52. Install the engine compartment upper RH heat shield.
^ Install the screw.

53. Install the battery positive cable.
^ Connect the battery positive cable to the BJB.
^ Tighten the nut to 25 Nm (18 lb.ft).
^ Install the grommet.
^ Install the BJB cover.

54. Connect the heater coolant hoses.
^ Secure the clips.

55. Secure the heater coolant hoses.
^ Secure in the clips.

56. Install the air cleaner assembly.
57. Connect the battery ground cable.
58. Refill and bleed the cooling system.
Complete coolant drain has been replaced with a coolant top up as only one (1) liter is lost.
For additional information, Service and Repair
59. Recharge the A/C system.
60. Bleed the brake system.
61. Install the wheels and tires.
62. Install the ride and handling optimization switch assembly.
63. Adjust the selector cable.
64. Install the transmission heat shield.
^ Tighten the bolts to 10 Nm (7 lb.ft).

65. Install the transmission undershield.
^ Tighten the bolts to 10 Nm (7 lb.ft).