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Full Frame and Body Mounting: Removal & Installation Land Rover Discovery IV

Frames, Subframes & Crossmembers 38 illustrations ~3836 words

INSTALLATION

  1. Install the crossmember. Tighten the nuts and bolts to 90 Nm (66 lb.ft).
  2. Install the transmission support insulator through-bolt and tighten to 175 Nm (129 lb.ft).
  3. Attach the HO2S wiring harness and bracket to the crossmember. Tighten the bolts to 10 Nm (7 lb.ft).
  4. Secure the 3 fuel lines. Secure in the clips.
  5. Connect the exhaust front mounting.
  6. Install the transmission undershield. Tighten the bolts to 10 Nm (7 lb.ft).

REMOVAL

Note. Some illustrations may show the body removed for clarity.

Scheme 1

Scheme 1: REMOVAL
Scheme 1: REMOVAL

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3
Scheme 3
  1. Raise and support the vehicle.
  2. Disconnect battery ground cable. For additional information, refer to: «Specification»(ref-579247-S04291360502013100600000) information.
  3. Disconnect the battery positive cable.
  4. Remove the rear bumper cover. For additional information, refer to: «Rear Bumper Cover»(ref-579163-S31298760542013100600000) information.
  5. Remove the spare wheel and tire.
  6. Remove both rear body mount dampers.
  7. Remove both rear body mass dampers.
  8. Remove the rear bumper cover lower brackets. Remove the 2 scrivets.
  9. Remove the rear bumper foam pads.
  10. Remove the bracket. Remove the 2 nuts.
  11. Remove the bracket. Remove the bolt.
  12. Using suitable tools, remove and discard the 4 rear body mass damper brackets. Item Description - Mig weld. (Right-hand is symmetrically opposite to left-hand).
  13. Using suitable tools, remove and discard the rear crossmember. Item Description - Mig weld. (Right-hand is symmetrically opposite to left-hand).

Scheme 4

Scheme 4: INSTALLATION
Scheme 4: INSTALLATION

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7
  1. Install the rear crossmember. For additional information: Welding. For additional information, refer to: «Body Repairs»(ref-579265-S36352466752013100600000) information. Corrosion protection. For additional information, refer to: «Corrosion Protection»(ref-579267-S04724643032013100600000) information. Tolerance checks. For additional information, refer to: «Body And Frame»(ref-579266-S28908645802013100600000) information.
  2. Install the rear bumper foam pads.
  3. Install the rear bumper cover lower brackets. Secure the 2 scrivets.
  4. Install the stiffener inside the chassis.
  5. Install the bracket. Tighten the bolt to 175 Nm.
  6. Remove the bracket. Tighten the M14 nut to 175 Nm. Tighten the M10 nut to 45 Nm
  7. Install both rear body mass dampers. Tighten the M8 bolts to 25 Nm. Tighten the M10 bolts to 40 Nm
  8. Install both rear body mount dampers. Tighten the bolts to 45 Nm.
  9. Install the spare wheel and tire.
  10. Install the rear bumper cover. For additional information, refer to: «Rear Bumper Cover»(ref-579163-S31298760542013100600000) information.
  11. Connect the battery positive cable. Tighten the battery terminal to 5 Nm.
  12. Connect the battery ground cable. For additional information, refer to: «Specification»(ref-579247-S04291360502013100600000) information.

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

Scheme 8

Scheme 8: REMOVAL
Scheme 8: REMOVAL

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26
  1. Raise and support the vehicle.
  2. Remove the wheels and tires.
  3. Disconnect the battery ground cable. For additional information, refer to: «Specification»(ref-579247-S04291360502013100600000) information.
  4. Drain the coolant. For additional information, refer to: «Cooling System Draining, Filling And Bleeding»(ref-579201-S24351426132013100600000) for V6 4.0L Petrol information. Refer to: «Cooling System Draining, Filling And Bleeding»(ref-579202-S01837698252013100600000) for V8 4.4L Petrol information.
  5. Recover the A/C refrigerant. For additional information, refer to: «Air Conditioning (A/C) System Recovery, Evacuation And Charging»(ref-579187-S19521526732013100600000) information.
  6. Remove the air cleaner assembly. For additional information, refer to: «Air Cleaner»(ref-579211-S04791780692013100600000) for V6 4.0L Petrol information. Refer to: «Air Cleaner»(ref-579212-S17209985202013100600000) for V8 4.4L Petrol information
  7. Remove the TCM. For additional information, refer to: «Four-Wheel Drive (4WD) Control Module»(ref-579216-S36797095962013100600000) information.
  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. Remove both front fender splash shields. For additional information, refer to: «Fender Splash Shield»(ref-579161-S18501756362013100600000) information.
  17. Remove the fender lower molding. Release the 2 clips. Repeat the above procedure for the other side.
  18. Remove the front bumper cover. For additional information, refer to: «Front Bumper Cover»(ref-579163-S34659971432013100600000) information.
  19. Remove the radiator lower air deflector. Remove the 3 clips.
  20. Remove the ride and handling optimization switch assembly. For additional information, refer to: «Ride And Handling Optimization»(ref-579166-S30289668142013100600000) information.
  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. Disconnect the brake booster vacuum hose. Release the clip.
  26. Disconnect the A/C compressor low pressure line. Discard the O-ring seal.
  27. 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. 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. 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. 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 moldings. For additional information, refer to: «Rear Quarter Panel Molding»(ref-579165-S18101428932013100600000) information.
  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. For additional information, refer to: «Rear Bumper Cover»(ref-579163-S31298760542013100600000) information.
  51. Remove the fuel filler flap assembly. For additional information, refer to: «Fuel Filler Door Assembly»(ref-579227-S23399180902013100600000) information.
  52. Release the fuel filler neck. Remove the bolt.
  53. 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. LH side rear: Disconnect the brake line. Position an absorbent cloth to collect fluid spillage. Disconnect the line union. Remove the clip.
  56. LH side rear: Disconnect the suspension air compressor intake line. Raise the vehicle on the lift.
  57. 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. Raise and support the body. Remove the 10 body mounts.
  1. Install the body mounts. Clean the component mating faces.
  2. 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. For additional information, refer to: «Fuel Filler Door Assembly»(ref-579227-S23399180902013100600000) information.
  13. Install the rear bumper cover. For additional information, refer to: «Rear Bumper Cover»(ref-579163-S31298760542013100600000) information.
  14. Install both rear fender splash shields.
  15. Install both rear fender moldings. For additional information, refer to: «Rear Quarter Panel Molding»(ref-579165-S18101428932013100600000) installation.
  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. 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. Connect the washer pump hoses.
  32. Connect the washer reservoir electrical connectors.
  33. 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. 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. For additional information, refer to: «Front Bumper Cover»(ref-579163-S34659971432013100600000) information.
  43. Install both front fender splash shields. For additional information, refer to: «Fender Splash Shield»(ref-579161-S18501756362013100600000) information.
  44. Install the fender lower molding. 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. For additional information, refer to: «Four-Wheel Drive (4WD) Control Module»(ref-579216-S36797095962013100600000) information.
  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. For additional information, refer to: «Air Cleaner»(ref-579211-S04791780692013100600000) for V6 4.0L Petrol information. Refer to: «Air Cleaner»(ref-579212-S17209985202013100600000) for V8 4.4L Petrol information.
  57. Connect the battery ground cable. For additional information, refer to: «Specification»(ref-579247-S04291360502013100600000) information.
  58. Refill and bleed the cooling system. For additional information, refer to: «Cooling System Draining, Filling And Bleeding»(ref-579201-S24351426132013100600000) for V6 4.0L Petrol information. Refer to: «Cooling System Draining, Filling And Bleeding»(ref-579202-S01837698252013100600000) for V8 4.4L Petrol information.
  59. Recharge the A/C system. For additional information, refer to: «Air Conditioning (A/C) System Recovery, Evacuation And Charging»(ref-579187-S19521526732013100600000) information.
  60. Bleed the brake system. For additional information, refer to: «Brake System Bleeding»(ref-579153-S19287220202013100600000) information.
  61. Install the wheels and tires.
  62. Install the ride and handling optimization switch assembly. For additional information, refer to: «Ride And Handling Optimization Switch»(ref-579166-S34055066162013100600000) information.
  63. Adjust the selector cable. For additional information, refer to: «Selector Lever Cable Adjustment»(ref-579222-S39446168122013100600000) for V6 4.0L Petrol information. Refer to: «Selector Lever Cable Adjustment»(ref-579223-S33783113522013100600000) for V8 4.4L Petrol information.
  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).

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

Scheme 27

Scheme 27: REMOVAL
Scheme 27: REMOVAL

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30

Scheme 31

Scheme 31
Scheme 31

Scheme 32

Scheme 32
Scheme 32

Scheme 33

Scheme 33
Scheme 33

Scheme 34

Scheme 34
Scheme 34

Scheme 35

Scheme 35
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Scheme 36

Scheme 36
Scheme 36

Scheme 37

Scheme 37
Scheme 37

Scheme 38

Scheme 38
Scheme 38
  1. Raise and support the vehicle. Raise the vehicle with the supports under the integrated body-frame.
  2. Disconnect the battery ground cable. For additional information, refer to: «Specification»(ref-579247-S04291360502013100600000) information.
  3. Remove the auxiliary battery tray. For additional information, refer to: «Auxiliary Battery Tray»(ref-579186-S03025977192013100600000) information.
  4. Remove the coolant expansion tank.
  5. Recover the A/C refrigerant. For additional information, refer to: «Air Conditioning (A/C) System Recovery, Evacuation And Charging»(ref-579187-S19521526732013100600000) information.
  6. Remove the air cleaner assembly.
  7. Remove the TCM. For additional information, refer to: «Four-Wheel Drive (4WD) Control Module»(ref-579216-S36797095962013100600000) information.
  8. Release the battery positive cable. Remove the BJB cover. Remove the nut. Release the grommet.
  9. Remove the battery compartment side wall. Release the 4 clips.
  10. Remove the battery compartment side wall extension.
  11. Disconnect the steering column lower shaft from the steering column. Remove and discard the Torx bolt.
  12. Release the battery positive cable bracket. Remove the 2 nuts.
  13. Release and disconnect the 2 engine wiring harness electrical connectors.
  14. Release and disconnect the 2 transmission wiring harness electrical connectors.
  15. Release the engine and transmission wiring harness cassettes, position the wiring harnesses aside. Release the 2 clips.
  16. Disconnect the brake booster vacuum hose. Release the clip.
  17. Disconnect the high and low-pressure A/C lines. Remove the 2 bolts. Remove and discard the 2 O-ring seals.
  18. Disconnect the fuel fired booster heater inlet and outlet coolant hoses. Release the 2 clips. Clamp the hoses
  19. Disconnect the A/C low-pressure switch electrical connector. Release the wiring harness.
  20. Disconnect the cooling fan electrical connector.
  21. Remove the radiator securing pegs. Depress the 2 clips.
  22. Disconnect the 2 heater coolant hoses. Release the clips. Clamp the two hoses.
  23. Remove the fuel filler door and inner assembly. Open the fuel filler door and remove the cap. Using a 2 mm metal rod, pierce the inner assembly and release the 4 clips. Release from the filler neck. Replace the filler cap.
  24. Release the fuel filler neck. Remove the bolt.
  25. Remove both front fender splash shields. For additional information, refer to: «Fender Splash Shield»(ref-579161-S18501756362013100600000) information.
  26. Remove the front bumper cover. For additional information, refer to: «Front Bumper Cover»(ref-579163-S34659971432013100600000) information.
  27. Disconnect the washer reservoir 3 electrical connectors.
  28. Disconnect the 2 washer pump hoses.
  29. Disconnect the ambient air temperature sensor harness. Release the clip. Disconnect the electrical connector.
  30. RH side front: Release the air suspension line from the wiring harness clip.
  31. RH side front: Release the ABS sensor lead. Release the 2 clips. Disconnect the electrical connector.
  32. RH side front: Disconnect the engine ground cable from the body. Remove the nut.
  33. RH side front: Disconnect the 2 body harness electrical connectors. Disconnect the 2 electrical connectors.
  34. RH side front: Release the body-frame harness. Release the 2 clips.
  35. RH side front: Release the brake line. Position an absorbent cloth to collect fluid spillage. Disconnect the line union. Remove the clip.
  36. LH side front: Release the ABS sensor lead. Release the 2 clips. Disconnect the electrical connector.
  37. LH side front: Disconnect the brake pad wear sensor electrical connector. Release from the 4 clips.
  38. LH side front: Release the 2 air lines. Release from the 5 clips.
  39. LH side front: Disconnect the 3 body harness electrical connectors.
  40. LH side front: Release the integrated body frame ground cable. Remove the nut. Release the 2 ground cables.
  41. LH side front: Release the brake line. Position an absorbent cloth to collect fluid spillage. Disconnect the line union. Remove the clip.
  42. Remove the rear bumper cover. For additional information, refer to: «Rear Bumper Cover»(ref-579163-S31298760542013100600000) information.
  43. RH side rear: Disconnect the brake line. Position an absorbent cloth to collect fluid spillage. Disconnect the line union. Remove the clip.
  44. LH side rear: Disconnect the 2 electrical connectors from the frame wiring harness.
  45. LH side rear: Disconnect the brake line. Position an absorbent cloth to collect fluid spillage. Disconnect the line union. Remove the clip.
  46. LH side rear: Disconnect the suspension air compressor intake line. Raise the vehicle on the lift.
  47. Release the parking brake emergency release cable.
  48. Remove the transmission undershield. Remove the 6 bolts.
  49. Remove the transmission heat shield. Remove the 4 bolts.
  50. Release the selector lever cable. Using an additional wrench, restrain the clamping bush and loosen the locknut. Compress the latch and release the cable.
  51. Remove the body mount retaining bolts. Remove the 10 spacing washers.
  52. Raise and support the body. Remove the 10 body mounts.
  1. Install the body mounts. Clean the component mating faces.
  2. 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. Raise the vehicle on the lift. 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 door assembly. Clean the component mating faces. Install the filler cap. Close the fuel filler door.
  13. Install the rear bumper cover. For additional information, refer to: «Rear Bumper Cover»(ref-579163-S31298760542013100600000) information.
  14. 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).
  15. LH side front: Connect the integrated body frame ground cable. Connect the ground cables. Tighten the nut to 25 Nm (18 lb.ft).
  16. LH side front: Connect the 3 body harness electrical connectors.
  17. LH side front: Secure the air lines to the clips.
  18. LH side front: Connect the brake pad wear sensor electrical connector. Secure in the clips.
  19. LH side front: Connect the ABS sensor lead. Connect the electrical connector. Secure in the clips.
  20. RH side front: Connect the 2 body harness electrical connectors.
  21. RH side front: Secure the body-frame harness. Secure with the 2 clips.
  22. 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).
  23. RH side front: Connect the engine ground strap to the body. Tighten the nut to 25 Nm (18 lb.ft).
  24. RH side front: Connect the ABS sensor lead. Connect the electrical connector. Secure the clips.
  25. RH side front: Install the air suspension line to the wiring harness clip.
  26. Connect the ambient air temperature sensor harness. Connect the electrical connector. Secure the clip.
  27. Connect the washer pump hoses.
  28. Connect the washer reservoir electrical connectors.
  29. Connect the high and low-pressure A/C lines. Clean the component mating faces. Install new O-ring seals. Tighten the bolt to 6 Nm (4 lb.ft).
  30. Connect the fuel fired booster heater coolant hoses. Secure with the clips.
  31. Connect the cooling fan electrical connector.
  32. Connect the A/C low-pressure switch electrical connector. Secure the wiring harness.
  33. Connect the brake booster vacuum hose to the intake manifold. Clean the component mating faces.
  34. Install the radiator securing pegs.
  35. Install the front bumper cover. For additional information, refer to: «Front Bumper Cover»(ref-579163-S34659971432013100600000) information.
  36. Install both front fender splash shields. For additional information, refer to: «Fender Splash Shield»(ref-579161-S18501756362013100600000) information.
  37. Connect the steering column lower shaft. Clean the component mating faces. Install a new patchlock bolt and tighten to 25 Nm (18 lb.ft).
  38. Align the engine, transmission harness and cassettes.
  39. Connect the 2 engine harness electrical connectors.
  40. Connect the 2 transmission harness electrical connectors.
  41. Install the engine and transmission harness cassettes.
  42. Install the TCM. For additional information, refer to: «Four-Wheel Drive (4WD) Control Module»(ref-579216-S36797095962013100600000) information.
  43. Install the battery compartment side wall extension.
  44. Install the battery compartment side wall. Secure the clips.
  45. 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.
  46. Connect the heater coolant hoses. Secure the clips.
  47. Install the air cleaner assembly.
  48. Install the coolant expansion tank.
  49. Connect the battery ground cable. For additional information, refer to: «Specification»(ref-579247-S04291360502013100600000) information.
  50. Recharge the A/C system. For additional information, refer to: «Air Conditioning (A/C) System Recovery, Evacuation And Charging»(ref-579187-S19521526732013100600000) information.
  51. Bleed the brake system. For additional information, refer to: «Brake System Bleeding»(ref-579153-S19287220202013100600000) information.
  52. Adjust the selector cable. For additional information, refer to: «Selector Lever Cable Adjustment»(ref-579222-S39446168122013100600000) for V6 4.0L Petrol information. Refer to: «Selector Lever Cable Adjustment»(ref-579223-S33783113522013100600000) for V8 4.4L Petrol information.
  53. Install the transmission heat shield. Tighten the bolts to 10 Nm (7 lb.ft).
  54. Install the transmission undershield. Tighten the bolts to 10 Nm (7 lb.ft).
  55. Check and top-up the coolant.
  56. Secure the fuel fired booster heater exhaust bracket.

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