Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20869
How To - Body Removal
You knew it would come eventually!
Well, actually, its a lie. Its not a How To, but more a basic guide. I would normally go into detail with every nut and bolt that needs to be removed, but I wont, due to the fact that will not be a job that everyone will be able to do, due to lack of a 2 post ramp etc, but its here for everyone to see what is involved in the job, regardless
This is also not a specific guide, due to differences between Auto + Manual vehicles, and also, differences in MY's. For reference, this is an 05MY Manual.
I will also say, that some forward planning is required. The car was needing a fair bit of work, including timing belts, brake pipes, clutch, rear upper wishbones etc. Yes, they could all be done with the body in place, but its much easier, and also quicker to lift the body.
Clutch replacement is about an hour with the body off, rear timing belt is quite literally, 30 seconds, rear upper wishbones are about 20 minutes, and no struggling with seized bolts etc.
Start off inside by removing the gearknob, lift and remove ATCM/switchpack. Undo 2 bolts att he front of the gearlever
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Push grommet through the floor, gearlever will rest on top of the box
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Remove mudflaps and front arch trims, for both sides
Remove both front wheel arch liners. For 05 + 06MY's, disconnect 3 mutliplugs in N/S/F wheelarch. Undo Earth terminal
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For 07MY>on, the wiring is up behind the passenger side headlight. This needs unplugged, and pulled down through the body
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Unplug brake wear sensor and wheel speed sensor. Undo brake pipe union, and unclip air pipes from body
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Unbolt FBH pipe from chassis, unplug all electrical connectors from washer bottle, and remove 2 pipes from washer pump. Note which way each pipe comes off
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In the O/S/F wheelarch, unplug 2 connectors, unplug wheelspeed sensor, and undo brake pipe
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07MY onwards, the connector is behind the drivers side headlight, This needs pulled down the side of the radiator and out the front of the car:
Remove towing electrics if fitted, and remove from body
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In the N/S/R wheelarch, unplug 2 big multiplugs. Also undo brake pipe
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In the O/S/R wheelarch, unbolt the fuel filler pipes from the body. The cap has to come off the end of the pipe to allow the pipe to come through the rubber grommet. I then removed the cap from the car to cover the end of the pipe to stop any crap getting in the tank.
No pictures of it bolted to the body, as you cant see very much, but here it is with the body already off
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Glow plug wiring stays with the body
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Remove O/S plastic trays, and unbolt steering column shaft. Also, disconnect vacuum pipes. Unbolt coolant pipes held onto bulkhead, and remove from heater matrix.
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Remove Battery, and N/S plastic trays. Disconnect transfer case ECU wiring, and engine module wiring. Also Autobox loom, if fitted
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Remove Coolant bottle and clamp pipe, remove fuel pipe from FBH, remove coolant hoses from FBH, undo A/C pipes, next to the battery tray. Unplug connector from A/C pipe, pull wiring for washer bottle up through the body
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Unplug air temp sensor
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Remove EPB emergency release cable from body. On 2007>on models, there is also an earth strap from the transfer box to the body
05 + 06MY's
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07MY>onwards
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Undo 10 body mount bolts, lower back to ground, re-position ramp, and Lift body
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As always, let me know if I have missed anything, or you have any additonal comments. If you need any more info, either post here or PM me
Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated My D3 Build Thread
Last edited by Disco_Mikey on 27th Apr 2013 9:27 pm. Edited 7 times in total
25th Feb 2012 7:31 am
DiscoDunc
Member Since: 08 May 2006
Location: Bristol
Posts: 16390
you missed one bit off though....
*Give it a wash Duncan
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25th Feb 2012 7:40 am
lancsamb
Member Since: 03 Feb 2006
Location: Blackpool where it does happen every night.
Posts: 433
and the hydraulic ramp to lift the body of the chassis would come in handy
That said an excellent pictoral walk through, and very well presented, thanksLandrover Discovery 3 TDV6 S 7 seat Automatic
Zambezi Silver my second love
25th Feb 2012 8:28 am
DSL Keeper of the wheelie bin
Member Since: 11 May 2006
Location: Off again! :-)
Posts: 73149
You left out the vital bit!!!
When does the Lucozade get sacrificed?
25th Feb 2012 8:30 am
John C
Member Since: 28 Aug 2007
Location: East Yorkshire
Posts: 3292
Quote:
I will also say, that some forward planning is required.
Ah - was hoping to get it done before the rugby...
Fascinating - thanks for sharing 2020 SDV6 D5 HSE, Carpathian Grey +
2022 Tesla Model Y LR... almost Carpathian Grey
Previously : 2005 TDV6 SE Auto, Cairns Blue (288K) - ours for 16 years
25th Feb 2012 8:39 am
Dave T
Member Since: 03 Jul 2009
Location: Glasgow
Posts: 6910
John C wrote:
Ah - was hoping to get it done before the rugby...
Fascinating - thanks for sharing
And you still can, it only takes about 3 hours and it's up! Mikey, do I get some commission for allowing you to practice on mine? Joined the BMWX5 45e group
1994 Defender 90
2015 RRS Corris Grey/Black roof
2016 D4 Graphite Santorini Black
2012 D4 XS Orkney Grey
2005 D3 S Maya Gold
Convoy for Heroes 2011
25th Feb 2012 8:45 am
Disco_Mikey
Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20869
Member Since: 28 Aug 2007
Location: East Yorkshire
Posts: 3292
Dave
How does yours run now - as good as before?2020 SDV6 D5 HSE, Carpathian Grey +
2022 Tesla Model Y LR... almost Carpathian Grey
Previously : 2005 TDV6 SE Auto, Cairns Blue (288K) - ours for 16 years
25th Feb 2012 8:51 am
Gareth Site Moderator
Member Since: 07 Dec 2004
Location: Bramhall
Posts: 26782
.... and refitting is the reverse of removal.
25th Feb 2012 9:01 am
Dave T
Member Since: 03 Jul 2009
Location: Glasgow
Posts: 6910
Better obviously............... on the lookout for a remap soon as well as leather and tints! Joined the BMWX5 45e group
1994 Defender 90
2015 RRS Corris Grey/Black roof
2016 D4 Graphite Santorini Black
2012 D4 XS Orkney Grey
2005 D3 S Maya Gold
Convoy for Heroes 2011
25th Feb 2012 10:02 am
Hairy Dan
Member Since: 19 Jan 2011
Location: Co. Durham
Posts: 12319
Great write-up and photos Cheers Ian
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Club N.E.R.D.S
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Discoless
25th Feb 2012 10:03 am
Dave T
Member Since: 03 Jul 2009
Location: Glasgow
Posts: 6910
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