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How To - Body Removal
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Disco_Mikey
 


Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 18509

Scotland 2005 Discovery 3 TDV6 HSE Auto Cairns BlueDiscovery 3
How To - Body Removal

You knew it would come eventually! Laughing

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 Thumbs Up

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

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Remove front bumper

EDIT: Front bumper removal Clicky

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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 Whistle

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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:

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Also, remove earth strap from the body

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Remove rear mudflaps, and rear bumper

EDIT: Rear bumper removal Clicky

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 Thumbs Up

Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated Mr. Green
 My D3 Build Thread

TDV8 Retrofit Build Thread 


Last edited by Disco_Mikey on 27th Apr 2013 10:27 pm. Edited 7 times in total 
Post #90137925th Feb 2012 8:31 am
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DiscoDunc
 


Member Since: 08 May 2006
Location: Bristol
Posts: 16390

England 2010 Discovery 4 3.0 SDV6 HSE Auto Aintree GreenDiscovery 4

Thumbs Up Bow down

you missed one bit off though....


*Give it a wash Laughing Thumbs Up
 Duncan
-----------------------------------------------------
If I'd known I was going to be so thirsty this morning I'd have drunk more beer last night.
D4 HSE MY13
FFRR 3.6 Vogue TDV8 SOLD
D4 HSE MY10 SOLD
D4 SE TECH MY15 SOLD
D4 XS MY12 SOLD
D4 HSE MY10 SOLD
D3 HSE MY06 - Re-Cycled Worldwide 
 
Post #90138025th Feb 2012 8:40 am
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lancsamb
 


Member Since: 03 Feb 2006
Location: Blackpool where it does happen every night.
Posts: 426

United Kingdom 2005 Discovery 3 TDV6 S Auto Zambezi SilverDiscovery 3

and the hydraulic ramp to lift the body of the chassis would come in handy Rolling with laughter Rolling with laughter

That said an excellent pictoral walk through, and very well presented, thanks
 Landrover Discovery 3 TDV6 S 7 seat Automatic
Zambezi Silver my second love 
 
Post #90140125th Feb 2012 9:28 am
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DSL
Keeper of the wheelie bin 


Member Since: 11 May 2006
Location: Travel itch scratching on pause. :-(
Posts: 65691

United Kingdom 

You left out the vital bit!!! Shocked Shocked

When does the Lucozade get sacrificed? Whistle
  
Post #90140325th Feb 2012 9:30 am
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John C
 


Member Since: 28 Aug 2007
Location: East Yorkshire
Posts: 3182

United Kingdom 2006 Discovery 3 TDV6 SE Auto Cairns BlueDiscovery 3

Quote:
I will also say, that some forward planning is required.


Laughing Ah - was hoping to get it done before the rugby...

Fascinating - thanks for sharing Smile
 2006 TDV6 SE Auto, Cairns Blue, Mine since 2007
Club 267K
Club AT2, Club Lenser, Club Trangia, Club Labrador, Club Chainsaw, Club Yorkshire Wink
...and club Replacement Engine 
 
Post #90140825th Feb 2012 9:39 am
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Dave T
 


Member Since: 03 Jul 2009
Location: Glasgow
Posts: 6250

England 

John C wrote:
Laughing Ah - was hoping to get it done before the rugby...

Fascinating - thanks for sharing Smile


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? Whistle Thumbs Up
 2015 RRS Corris Grey/Black roof
1994 Defender 90

2016 D4 Graphite Santorini Black
2012 D4 XS Orkney Grey
2005 D3 S Maya Gold

Convoy for Heroes 2011 
 
Post #90141325th Feb 2012 9:45 am
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Disco_Mikey
 


Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 18509

Scotland 2005 Discovery 3 TDV6 HSE Auto Cairns BlueDiscovery 3

Sure do Dave, you can have some of my Thanks Whistle Thumbs Up
 My D3 Build Thread

TDV8 Retrofit Build Thread 
 
Post #90141525th Feb 2012 9:48 am
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John C
 


Member Since: 28 Aug 2007
Location: East Yorkshire
Posts: 3182

United Kingdom 2006 Discovery 3 TDV6 SE Auto Cairns BlueDiscovery 3

Laughing Dave Thumbs Up
How does yours run now - as good as before?
 2006 TDV6 SE Auto, Cairns Blue, Mine since 2007
Club 267K
Club AT2, Club Lenser, Club Trangia, Club Labrador, Club Chainsaw, Club Yorkshire Wink
...and club Replacement Engine 
 
Post #90141725th Feb 2012 9:51 am
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Gareth
Site Moderator 


Member Since: 07 Dec 2004
Location: Bramhall
Posts: 25029

United Kingdom 2013 Discovery 4 3.0 SDV6 HSE Lux Auto Fuji WhiteDiscovery 4

.... and refitting is the reverse of removal. Bow down

  
Post #90142125th Feb 2012 10:01 am
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Dave T
 


Member Since: 03 Jul 2009
Location: Glasgow
Posts: 6250

England 

Better obviously............... on the lookout for a remap soon as well as leather and tints! Whistle Whistle
 2015 RRS Corris Grey/Black roof
1994 Defender 90

2016 D4 Graphite Santorini Black
2012 D4 XS Orkney Grey
2005 D3 S Maya Gold

Convoy for Heroes 2011 
 
Post #90144725th Feb 2012 11:02 am
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Hairy Dan
 


Member Since: 19 Jan 2011
Location: Co. Durham
Posts: 12319

United Kingdom 2016 Discovery 4 3.0 TDV6 Landmark LE Auto Santorini BlackDiscovery 4

Great write-up and photos Thumbs Up
 Cheers Ian
--------------------
Club N.E.R.D.S
Kielder 4x4 Safari
Discoless 
 
Post #90145025th Feb 2012 11:03 am
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Dave T
 


Member Since: 03 Jul 2009
Location: Glasgow
Posts: 6250

England 

on the subject of remaps, just found this

http://www.autologic-diagnos.co.uk/media/u..._EN05w.pdf
 2015 RRS Corris Grey/Black roof
1994 Defender 90

2016 D4 Graphite Santorini Black
2012 D4 XS Orkney Grey
2005 D3 S Maya Gold

Convoy for Heroes 2011 
 
Post #90145225th Feb 2012 11:06 am
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Disco_Mikey
 


Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 18509

Scotland 2005 Discovery 3 TDV6 HSE Auto Cairns BlueDiscovery 3



Dave, speak to grahamk, his D3 has had an Autologic Remap Thumbs Up

On another note, you have a P.M

Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated Mr. Green
 My D3 Build Thread

TDV8 Retrofit Build Thread 
 
Post #90145725th Feb 2012 11:17 am
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Kingmav66
 


Member Since: 20 Jul 2010
Location: Gloucestershire
Posts: 1349

England 2006 Discovery 3 TDV6 HSE Auto Buckingham BlueDiscovery 3

Nice guide Mikey. There's quite a bit involved to do this Shocked
Just out of interest, how long does it take you on average, to lift a body?
  
Post #9293258th May 2012 12:15 pm
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ronp
 


Member Since: 29 Nov 2006
Location: 🌲Gall-Ghaidhealaibh🌲
Posts: 13794

Scotland 2014 Discovery 4 3.0 SDV6 HSE Auto Corris GreyDiscovery 4

Very inspiring thread DM .......

..... think I might pop out at lunch time and give it a go Laughing

Thumbs Up
 🌲🌲in the forest🌲🌲

Member of SLROC (Scottish Land Rover owners club)

The older I get, the better I used to be.😕 
 
Post #9293268th May 2012 12:20 pm
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