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Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual
Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual
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FRONT SUSPENSION 60-18 REPAIRS Refit 1.Ensure sensor and mounting bracket mating surfaces are clean. 2.Position height sensor to mounting bracket, fit Allen screws and tighten to 5 Nm (3.7 lbf.ft). 3.Connect link to height sensor, fit nut and tighten to 8 Nm (6 lbf.ft). CAUTION: Ensure height sensor arm is pointing outwards. 4.Connect multiplug and secure harness with cable tie, taking care not to exert excessive tension on wires as they enter multiplug. CAUTION: Ensure O ring seal is correctly located in multiplug. 5.Fit road wheel and tighten nuts to 140 Nm (103 lbf.ft). 6.Remove stands and lower vehicle. 7.If a replacement sensor has been fitted, use TestBook/T4 to re-calibrate system. + FRONT SUSPENSION, ADJUSTMENTS, Calibrate - air suspension. Tie rod $% 60.40.09 Remove 1.Raise front of vehicle. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. 2.Remove road wheel. 3.Remove nut securing height sensor link to lower arm and release link. 4.Loosen bolt securing lower arm to subframe one quarter of a turn. 5.Remove nut securing ball joint to lower arm. 6.Using LRT-54-027 release lower arm ball joint and disconnect lower arm from hub. CAUTION: Ensure ball joint seal is not damaged. A damaged seal will lead to premature failure of the joint. M60 0789LRT -54-027
FRONT SUSPENSION REPAIRS 60-19 7.Loosen bolt securing tie rod to subframe one quarter of a turn. 8.Remove nut securing tie rod to ball joint. 9.Using LRT-54-027 release tie rod from ball joint 10.Remove bolt securing tie rod to subframe. Discard bolt. 11.Remove tie rod. Refit 1.Clean ball joint tapers and taper seats. 2.Fit tie rod, fit new bolt but do not tighten at this stage CAUTION: Nuts and bolts must be tightened with weight of vehicle on suspension. 3.Connect tie rod to ball joint, fit nut and tighten to 80 Nm (59 lbf.ft). CAUTION: Ensure ball joint seal is not damaged. A damaged seal will lead to premature failure of the joint. 4.Connect lower arm ball joint to hub, fit nut and tighten to 80 Nm (59 lbf.ft). 5.Replace bolt securing lower arm to subframe but do not tighten at this stage.6.Fit road wheel(s) and tighten nuts to 140 Nm (103 lbf.ft). 7.Remove stands and lower vehicle. 8.Tighten bolt securing lower arm to subframe to 165 Nm (121 lbf.ft) plus a further 90°. 9.Tighten bolt securing tie rod to subframe to 165 Nm (121 lbf.ft) plus a further 90°. 10.Check front wheel alignment. M60 0787 LRT -54-027
FRONT SUSPENSION 60-20 REPAIRS Bushes - tie rods $% 60.40.12 Caution: Bushes must be replaced in pairs. Remove 1.Remove tie rod. + FRONT SUSPENSION, REPAIRS, Tie rod. 2.Using LRT-60-032/1 and LRT-60-032/2 press bush from tie rod. Refit 1.Ensure bush and bore are clean and free from grease. 2.Align bush as shown and fit bush using LRT- 60-032/1 and LRT-60-032/3. 3.Fit tie rod. + FRONT SUSPENSION, REPAIRS, Tie rod. 4.Repeat procedure for other side. Air reservoir $% 60.50.03 The pressure switch in the air reservoir must not be removed. It is supplied with the air reservoir. When removing Voss connectors from any air suspension component the connector must be left attached to the air pipe being removed. Do not remove the connector from the air pipe. Removing the connector from the air pipe could cause the connector to scratch the pipe and increase the likelihood of leaks. Remove 1.Raise front and rear of vehicle and support under body. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. 2.Remove valve block assembly. + FRONT SUSPENSION, REPAIRS, Valve block assembly. 3.Remove 6 bolts and 2 nuts securing fuel tank shield and lower shield for access.
FRONT SUSPENSION REPAIRS 60-21 4.Remove 4 bolts securing air reservoir, lower reservoir and disconnect multiplug from pressure switch. CAUTION: Do not remove the pressure switch from the air reservoir. 5.Remove 2 clips securing air pipes and remove reservoir. NOTE: Do not carry out further dismantling if component is removed for access only. 6.Remove nuts securing valve block mounting studs and remove studs.Refit 1.Fit valve block mounting studs and tighten nuts. CAUTION: Ensure the rubber blocks are correctly seated into depressions in valve block. 2.If fitting a new reservoir, remove air connector from new assembly. 3.Position reservoir, secure air pipes and connect multiplug. CAUTION: Take care not to trap pipes under reservoir brackets 4.Fit bolts securing air reservoir to body and tighten to 8 Nm (6 lbf.ft). 5.Fit bolts and nuts securing fuel tank shield and tighten to 25 Nm (18 lbf.ft). 6.Fit valve block. + FRONT SUSPENSION, REPAIRS, Valve block assembly. 7.Remove stands and lower vehicle. M60 0807
FRONT SUSPENSION 60-22 REPAIRS Electronic Control Unit (ECU) - air suspension $% 60.50.04 If the ECU is to be replaced then Testbook/T4 must be connected and correct procedures adhered to, prior to battery disconnection. Remove 1.Remove passengers side lower fascia finisher. + INTERIOR FITTINGS, REPAIRS, Finisher - lower - passengers side. 2.Release 2 clips and withdraw ECU from holder. 3.Disconnect 2 multiplugs from ECU. 4.Remove ECU. Refit 1.Position new ECU, connect multiplugs and secure ECU in holder. 2.Fit passengers side fascia lower finisher. + INTERIOR FITTINGS, REPAIRS, Finisher - lower - passengers side. 3.Use TestBook/T4 to re-calibrate system. + FRONT SUSPENSION, ADJUSTMENTS, Calibrate - air suspension. Air supply unit $% 60.50.10 There is no need to depressurise the suspension in this procedure. Remove 1.Remove spare wheel cover. 2.Release wing nut securing spare wheel to compressor housing, remove bolt and collect cup. 3.Remove spare wheel. 4.Remove 4 bolts securing air supply unit to body. M60 0812
FRONT SUSPENSION REPAIRS 60-23 5.Depress locking ring and disconnect air pipe from air supply unit. 6.Disconnect multiplug from air supply unit. 7.Noting their exact fitted positions, release harness/pipe clips and remove cable ties. 8.Rotate harness multiplug and remove from mounting bracket. 9.Remove air supply unit. Refit 1.Position air supply unit, fit and secure multiplug in mounting bracket. 2.Fit 4 bolts securing air supply unit to body and tighten to 8 Nm (6 lbf.ft). 3.Connect air pipe and supply unit multiplug. CAUTION: Ensure large grommet in body is correctly fitted, failure to do so will result in water ingress. 4.Secure harness/pipe in clips and replace cable ties in exact positions as noted on removal. CAUTION: Pipe/harness may be trapped by spare wheel if not correctly positioned. 5.Position spare wheel in well, fit retaining cup and secure wing nut. 6.Fit spare wheel cover. Valve block assembly $% 60.50.11 Do not depressurise air suspension system before raising vehicle When removing Voss connectors from any air suspension component, the connector must be left attached to the air pipe being removed. Do not remove the connector from the air pipe. Removing the connector from the air pipe could cause the connector to scratch the pipe and increase the likelihood of leaks. The valve block can be checked for correct operation using TestBook/T4. Remove 1.Raise front of vehicle and support under body. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. 2.Depressurise suspension. + FRONT SUSPENSION, ADJUSTMENTS, Air suspension system - depressurise and repressurise. 3.Remove 2 speed nuts securing closing panel. Release and remove panel. M60 0796 M80 0801
FRONT SUSPENSION 60-24 REPAIRS 4.Disconnect pipe from air reservoir. CAUTION: Before disconnecting or removing components, ensure the immediate area around joint faces and connections are clean. Plug open connections to prevent contamination. 5.Noting their fitted positions, disconnect 4 pipes from valve block. 6.Remove 3 nuts securing valve block. 7.Release valve block, depress locking ring and disconnect compressor feed pipe. 8.Disconnect 3 multiplugs and remove valve block. NOTE: Do not carry out further dismantling if component is removed for access only. 9.Remove pipe from valve block.Refit 1.If fitting a new valve block, remove Voss connectors from new block. 2.Fit pipe to valve block but do not fully tighten union at this stage. CAUTION: Ensure air pipe connections are clean. 3.Position valve block, connect multiplugs and compressor feed pipe. 4.Locate valve block and fit and tighten nuts. 5.Connect pipes to valve block and tighten unions to 3.5 Nm (2.6 lbf.ft). 6.Connect pipe to air reservoir and tighten both unions to 3.5 Nm (2.6 lbf.ft). 7.Fit closing panel and secure with speed nuts. 8.Pressurise suspension. + FRONT SUSPENSION, ADJUSTMENTS, Air suspension system - depressurise and repressurise. 9.Remove stands and lower vehicle. M60 0802
FRONT SUSPENSION REPAIRS 60-25 Valve assembly - cross link $% 60.50.13 On later models the cross link valve assembly is not fitted. Remove 1.Raise front of vehicle and support under body. 2.Depressurise front air suspension springs. + FRONT SUSPENSION, ADJUSTMENTS, Air suspension system - depressurise and repressurise. 3.Remove RH front road wheel. 4.Remove 5 hexagonal headed screws securing wheel arch liner. 5.Remove screw securing wheel arch liner. 6.Release wheel arch liner for access. 7.Noting their fitted positions, disconnect 4 pipes from cross link valve. CAUTION: Before disconnecting or removing components, ensure the immediate area around joint faces and connections are clean. Plug open connections to prevent contamination.8.Disconnect multiplug. 9.Remove 3 bolts securing cross link valve to body. Collect rubber spacers. 10.Remove cross link valve. Refit 1.If fitting a new cross link valve, remove air connectors from new valve. 2.Position cross link valve, fit bolts and spacers, and tighten to 4.6 Nm (3.4 lbf.ft). 3.Connect multiplug. 4.Connect pipes to cross link valve and tighten unions to 3.5 Nm (2.6 lbf.ft). CAUTION: Ensure air pipe connections are clean. 5.Locate wheel arch liner and secure with screws. 6.Fit road wheel and tighten nuts to 140 Nm (103 lbf.ft). 7.Pressurise suspension. + FRONT SUSPENSION, ADJUSTMENTS, Air suspension system - depressurise and repressurise. 8.Remove stands and lower vehicle. M60 0810
REAR SUSPENSION ADJUSTMENTS 64-1 REAR SUSPENSION ADJUST ME NTS Suspension - depressurise and repressurise $% 64.50.38 Depressurise 1.Depressurise suspension using TestBook/T4. WARNING: The air suspension system is pressurised up to: lUp to VIN 106309 - 13.7 Bar (199 lbf/in2) lFrom VIN 106310 - 11.8 Bar (171 lbf/in2) WARNING: Ensure dirt or grease does not enter the system. Wear hand, ear and eye safety protection when working on the system. Repressurise 1.Repressurise suspension using TestBook/T4. CAUTION: The air springs must be fully pressurised before the weight of the vehicle is applied to them.