: | Mar 15, 2007 |
In this procedure, the body is removed from the integrated body-frame. This procedure can only be performed using a 2-Post ramp. |
. | Open the upper liftgate and lower tailgate. |
. | Disconnect the battery ground cable. |
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Raise and support the vehicle. |
. | Remove the floor console upper panel. |
. | Release the gearshift lever mounting bracket.
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. | Remove the wheels and tires. |
. | Drain the cooling system. |
. | Recover the air conditioning (A/C) refrigerant.
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. | Remove the air cleaner assembly. |
. | Disconnect the engine coolant temperature (ECT)
sensor electrical connector.
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. | Remove the four-wheel drive (4WD) control
module. |
. | Release the battery positive cable.
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. | Remove the battery compartment side wall.
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. | Release the heater pipes.
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. | Remove the battery tray.
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. | Disconnect the heater supply and return hoses.
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. | Remove the auxiliary battery tray. |
. | Release and disconnect the 2 engine wiring
harness electrical connectors. ![]() |
. | Release and disconnect the 2 transmission wiring
harness electrical connectors. ![]() |
. | Release the engine and transmission wiring
harness cassettes, position the wiring harnesses aside.
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. | Disconnect the glow plug electrical connectors.
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Disconnect the high and low-pressure A/C lines.
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. | Disconnect the A/C low-pressure switch
electrical connector.
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Disconnect the brake booster vacuum hose. ![]() |
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Release the steering column lower shaft.
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. | Remove both front fender splash shields. |
. | Remove both fender lower mouldings.
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. | Remove the hood latch panel. |
. | LH side behind the front headlamp: Disconnect
the frame wiring harness electrical connector. ![]() |
. | LH side behind the front panel: Disconnect the 2 electrical connectors from the frame wiring harness. |
. | LH side behind headlamp: Release the 2 clips
from the inner fender. ![]() |
. | Disconnect the fuel fired booster heater inlet
and outlet coolant hoses.
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. | Remove the windshield washer reservoir filler
neck. ![]() |
. | Disconnect the 2 hoses from the coolant
expansion tank.
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. | Remove the coolant expansion tank.
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. | Disconnect the cooling fan electrical connector.
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. | Release the battery positive cable.
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. | Disconnect the fuel fired booster heater fuel
line. ![]() |
. | Disconnect the 3 electrical connectors from the washer reservoir. |
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Disconnect the 2 washer pump hoses. ![]() |
. | LH side front: Release the ABS sensor lead.
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. | LH side front: Disconnect the brake pad wear
sensor electrical connector.
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. | LH side front: Release the 2 air lines.
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. | LH side front: Release the integrated body frame
ground cables.
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LH side front: Release the brake line.
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. | Disconnect the 3 electrical connectors from the
frame wiring harness.
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. | RH side front: Release the air suspension line from the wiring harness clip. |
. | RH side front: Release the ABS sensor lead.
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. | RH side front: Release the engine ground cable
from the integrated body frame.
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RH side front: Release the brake line.
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. | Disconnect the ambient air temperature sensor
electrical connector.
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. | Disconnect the 2 electrical connectors from the
frame wiring harness.
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. | Remove the RH rear quarter panel moulding. |
. | Remove the RH rear fender splash shield.
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. | Remove the rear bumper cover. |
. | Release the fuel filler neck.
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RH side rear: Disconnect the brake line.
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. | LH side rear: Disconnect the 2 electrical
connectors from the frame wiring harness. ![]() |
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LH side rear: Disconnect the brake line.
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LH side rear: Disconnect the suspension air compressor intake line. ![]() |
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Release the parking brake emergency release cable. ![]() |
. | Remove the transmission undershield.
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. | Remove the transmission heat shield.
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. | Release the selector lever cable.
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. | Remove the body mount retaining bolts.
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. | Temporarily install the road wheels and tires.
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:
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Using an assistant raise and support the body.
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Using an assistant install the body to the integrated body frame.
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. | Remove the tie down straps securing the body. |
. |
Raise and support the vehicle.
|
. | Tighten the integrated body frame to body bolts to 133 Nm (98 lb.ft). |
. | Remove the wheels and tires. |
. | Attach the selector cable. |
. | Secure the parking brake emergency release
cable.
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LH side rear: Connect the suspension air compressor intake line.
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. | LH side rear: Connect the brake line.
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. | LH side rear: Connect the 2 body harness electrical connectors. |
. | RH side rear: Connect the brake line.
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. | Secure the fuel filler neck.
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. | Install the RH rear fender splash shield. |
. | Install the rear bumper cover. |
. | Install the RH rear quarter panel moulding. |
. | Connect the 3 electrical connectors to the frame
wiring harness.
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. | LH side front: Connect the brake line.
|
. | LH side front: Connect the integrated body frame
ground cable.
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. | LH side front: Secure the air lines to the clips. |
. | LH side front: Connect the brake pad wear sensor
electrical connector.
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. | LH side front: Connect the ABS sensor lead.
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. | Secure the fuel fired booster heater exhaust bracket. |
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Connect the washer pump hoses. |
. | Connect the washer reservoir electrical connectors. |
. | RH side front: Secure the body-frame harness.
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. | RH side front: Connect the brake line.
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. | RH side front: Connect the ABS sensor lead.
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. | RH side front: Install the air suspension line to the wiring harness clip. |
. | RH side front: Connect the engine ground cable
to the body.
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. | Connect the ambient air temperature sensor
harness.
|
. | Connect the 2 electrical connectors to the frame
wiring harness.
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. | Connect the fuel fired booster heater coolant
hoses.
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. | Secure the battery positive cable. |
. | Install the hood latch panel. |
. | Reposition the frame wiring harness through the inner fender. |
. | LH side behind the front headlamp: Connect the frame wiring harness electrical connector. |
. | LH side behind the front panel: Connect the 2 electrical connectors to the frame wiring harness. |
. | LH side behind headlamp: Secure the 2 clips to the inner fender. |
. | Install the coolant expansion tank.
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. | Connect the coolant hoses to the expansion tank.
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. | Install the windshield washer reservoir filler neck. |
. | Secure the power steering fluid reservoir.
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. | Connect the cooling fan electrical connector. |
. | Install both front fender splash shields. |
. | Install the fender lower moulding.
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Connect the high and low-pressure A/C lines.
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. | Connect the A/C low-pressure switch electrical
connector.
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. | Connect the wiring harness to the glow plugs.
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. | Install the 4WD control module. |
. | Connect the ECT sensor electrical connector.
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. | Align the engine, transmission harness and cassettes. |
. | Connect the 2 engine harness electrical connectors. |
. | Connect the 2 transmission harness electrical connectors. |
. | Install the engine and transmission harness cassettes. |
. | Install the auxiliary battery tray. |
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Connect the steering column lower shaft.
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. | Connect the heater coolant hoses.
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Connect the brake booster vacuum hose. |
. | Install the battery tray.
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. | Install the battery compartment side wall extension. |
. | Install the battery compartment side wall.
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. | Install the battery positive cable.
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. | Install the floor console upper panel. |
. | Secure the gearshift lever mounting bracket.
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. | Install the air cleaner assembly. |
. | Connect the battery ground cable. |
. | Refill and bleed the cooling system. |
. | Recharge the A/C system. |
. | Bleed the brake system. |
. | Install the wheels and tires.
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. | Adjust the selector cable. |