Land Rover Range Rover Body Repair Rover Manual

							ELECTRONIC AIR SUSPENSION
3
DESCRIPTION AND OPERATION DESCRIPTION OF COMPONENTS
Electrical control unit - ECU
The ECU is located underneath the front left hand
seat. The ECU maintains the requested vehicle ride
height by adjusting the volume in each air spring. It is
connected to the cable assembly by a 35 way
connector. To ensure safe operation the ECU has
extensive on board diagnostic and safety features.
The ECU must be replaced in case of failure.
Air compressor
NOTE: The air compressor and valve block
are contained in the under bonnet unit
mounted on the left hand inner wing.
The air compressor provides system pressure. A
thermal switch is incorporated which cuts out
compressor operation at 120Ê C. An air filter is fitted to
the compressor head. The filter is renewed every
40,000 kms. (24,000 miles).
Air dryer
The air dryer is connected into the air line between the
compressor and reservoir. It is mounted on the engine
air cleaner box. The dryer removes moisture from
pressurised air entering the system. All air exhausted
from the system passes through the dryer in the
opposite direction. The air dryer is regenerative in that
exhaust air absorbs moisture in the dryer and expels it
to atmosphere.
The air dryer is non-servicable, designed to last the
life of the vehicle. However, if any water is found in
the system, the air dryer must be replaced.
CAUTION: If the air dryer is removed from
the vehicle the ports must be plugged to
prevent moisture ingress.Valve block
The valve block controls the direction of air flow. Air
flow to and from the air springs is controlled by seven
solenoid operated valves, one for each spring plus an
inlet, exhaust and outlet. In response to signals from
the ECU, the valves allow high pressure air to flow in
or out of the air springs according to the need to
increase or decrease pressure. A diaphragm valve
operated by the solenoid outlet valve ensures that all
exhausted air passes through the air dryer.
Mounted on the valve block is a pressure switch which
senses air pressure and signals the ECU to operate
the compressor when required.The compressor will
operate when the pressure falls between 7.2 and 8.0
bar. It will cut out at a rising pressure of between 9.5
and 10.5 bar.
The valve block contains the following serviceable
components: solenoid coils 1 to 6, drive pack and
pressure switch.
The valve block must only be dismantled after the
correct diagnosis procedure.
Reservoir
The 10 litre reservoir is mounted on the right hand
side of the chassis. One connection acts as air inlet
and outlet for the rest of the system. The reservoir
stores compressed air between set pressure levels.
The reservoir drain plug requires removing to check
for moisture in the system every 40,000 kms. (24,000
miles).
Height sensors
Four potentiometer type height sensors signal vehicle
height information to the ECU. The potentiometers are
mounted on the chassis and activated by links to the
front radius arms and rear trailing links. A height
sensor must be replaced in case of failure, and the
vehicle recalibrated using TestBook. 
						

							60FRONT SUSPENSION NEW RANGE ROVER
4
DESCRIPTION AND OPERATION Air springs - front and rear
The air springs consist of the following components:
1. Top plate
2. Rolling rubber diaphragm
3. Piston
Front and rear air springs are of similar constuction
but are NOT interchangeable. The diaphragm is not
repairable, if failure occurs the complete air spring
must be replaced
Driver controls
Mounted in the centre of the dashboard, the driver
controls consist of an UP/DOWN switch, an INHIBIT
switch and a height setting indicator. For full
description.
See this section.
Relays, fuses
Located in the under bonnet fuse/relay box are 2
relays, plus 10, 20 and 30 amp fuses.DRIVER CONTROLS
The driver controls are located in the centre of the
fascia. The controls consist of:
1.The HEIGHT CONTROL is a press and release
type rocker switch which is used to select the
required ride height. The vehicle will not respond
until switch is released. All movements selected
by operation of this switch are indicated by the
ride height indicator lights located next to the
switch.
2.The INHIBIT switch is a mechanically latching
switch. When selected it modifies the automatic
height changes of the system, for further details.
See Electrical Trouble Shooting Manual.
Selection of inhibit is indicated by illumination of
the switch tell-tale lamp, which is also bulb
tested with the ride height indicator.
3.High indicator light.
4.Standard indicator light.
5.Low indicator light.
6.Access indicator light.
7.Instrument pack warning light.
Indicator lights
When the ignition key is turned to position 2 all four
indicator lights, the air suspension warning light and
the inhibit switch will be illuminated continuously.
When the engine is started, the lights will remain
illuminated for 2 seconds, after which the current ride
height will be indicated. Two indicators will be
illuminated if the vehicle is between ride heights, with
the selected height flashing. When the new height is
achieved the indicator will be illuminated constantly
and the previous height indicator extinguished. The
inhibit switch indicator is illuminated while it is
activated. Both switches are illuminated with sidelights
switched on. Additional driver information is given by
the message centre in the instrument pack. For details
of the messages.
See this section.
Air suspension warning lamp
This amber lamp is located in the instrument pack.
The lamp will be constantly illuminated when driving at
high ride height and will flash when vehicle is at
extended height. The lamp will also illumunate if a
fault within the system is detected. A bulb check is
provided when the ignition switch is turned to position
2 and for 2 seconds after vehicle start. 
						

							ELECTRONIC AIR SUSPENSION
5
DESCRIPTION AND OPERATION HEIGHT SETTINGS
Standard ride height
With the Inhibit switch off (unlatched), at speeds
below 80 km/h (50 mph) the standard ride height
indicator will be illuminated.
Standard vehicle ride height is maintained under all
load conditions. This also maintains headlamp
levelling.
Low ride height
Low ride height is automatically selected when the
vehicle speed exceeds 80 km/h (50 mph) for at least
30 seconds with the inhibit switch off. Low ride height
indicator lamp will flash during height change and
standard ride height indicator will extinguish when low
ride height is attained.
Standard ride height is automatically selected when
the vehicle speed drops below 56 km/h (35 mph) for
at least 30 seconds with the inhibit switch off.
The driver can select low ride height at any speed.
With the vehicle at low ride height, depressing the
inhibit switch (latched) will result in the vehicle
maintaining low ride height regardless of speed.
The height control switch can be used to change
between low and standard ride heights regardless of
speed.
Access mode
This position eases access to and from the vehicle.
With the vehicle stationary, doors and tailgate closed,
park brake applied, foot brake released and gearshift
in Park on automatic vehicles, press and release the
down switch. The vehicle will descend to access
mode. While the vehicle is descending, the access
indicator will flash. When access mode is attained, the
indicator will remain constantly illuminated, and
standard ride height lamp will be extinguished.
Access mode can be selected up to 40 seconds
before stopping vehicle. On stopping, applying the
handbrake, releasing the foot brake and selecting
Park on automatic vehicles, the vehicle will lower to
access mode.It is possible to select access up to 40 seconds after
switching engine off.
NOTE: Opening a door or tailgate will
immediately stop vehicle height change.
When the door is closed, the height
change will be completed. If the door is open for
more than thirty seconds, the system will need
reminding of the new height when the door is
closed.
Driving the vehicle will result in vehicle rising
automatically to standard ride height. Alternatively
standard ride height can be achieved by closing all
doors, starting engine and pressing the up switch. The
standard indicator will flash during the change. When
standard ride height is attained the indicator will
remain constantly illuminated and access indicator will
be extinguished.
Crawl mode
In areas where height is restricted, the vehicle may be
driven in access mode. To achieve this, ensure the
inhibit switch is unlatched and select access mode.
When access height is achieved, press the inhibit
switch, the lamp will be illumunated. The message
centre in the instrument binnacle will beep three times
and display AIRSUS ISOLATED. The vehicle may
now be driven at speeds up to 32 km/h (20 mph).
If the vehicle is accelerated to 16 km/h (10 mph) the
message centre will beep three times and display
SLOW 20 MPH (32 KM/H) MAX.
If speed exceeds 40 km/h (25 mph) the vehicle will
rise to low profile, with low warning flashing. On
slowing to 32 km/h (20 mph) the vehicle will lower to
access mode with access warning illuminated.
When speed falls below 8 km/h (5 mph) the message
centre will beep three times and display AIRSUS
ISOLATED.
To cancel crawl mode, release the inhibit switch or
depress the up switch. 
						

							60FRONT SUSPENSION NEW RANGE ROVER
6
DESCRIPTION AND OPERATION High ride height
This position is used to improve approach and
departure angles and when wading. When at standard
ride height, pressing the up switch will select high ride
height provided the road speed is below 56 km/h (35
mph). The high ride height indicator will flash during
the height change. When the change is complete the
indicator will remain constantly illuminated, and
standard ride height indicator will be extinguished.
The indicator in the instrument pack will also be
illuminated. If speed exceeds 56 km/h (35 mph), the
vehicle will return to standard profile.
Extended ride height
This position is achieved if chassis is grounded
leaving wheel or wheels unsupported. Initial ECU
reaction is to lower (deflate) affected springs. After a
timed period the ECU detects no height change, it
therefore reinflates springs to extended profile in an
attempt to regain traction. The position will be held for
10 minutes, after which time the vehicle will
automatically return to standard ride height.
Pressing the down switch will lower vehicle 20 mm to
high profile.
If vehicle speed exceeds 56 km/h (35 mph) the
vehicle will immediately lower to standard ride height.
This speed could be achieved, for example, by
wheelspin.VEHICLE TRANSPORTATION
New vehicles are transported from the factory with the
EAS system electronically frozen in access mode.
When road speed exceeds 40 km/h (25 mph), the
vehicle will rise to low ride height. It will return to
access mode if speed falls below 38.4 km/h (24 mph).
This condition is cancelled at pre-delivery inspection,
by entering the appropriate command via TestBook.
Vehicle transportation/recovery
CAUTION: When an air suspension vehicle
is secured to a transporter using the
chassis lashing eyes, there is a possibility
due to air leakage, self levelling or operation of
ride height controls that the tension of the
securing straps will be lost. To prevent this the
ride height should be set to access mode before
securing to transporter.
If the engine cannot be run and the vehicle is not in
access mode, the vehicle can be transported, but it
must be secured to the transporter by the roadwheels,
not the chassis.
ELECTRICAL TROUBLESHOOTING
For electrical details of the air suspension circuit.
See
Electrical Trouble Shooting Manual. 
						

							ELECTRONIC AIR SUSPENSION
7
DESCRIPTION AND OPERATION SYSTEM OPERATION
Numbers refer to pneumatic circuit diagram
Air is drawn through the inlet filter (1) to the
compressor (2), where it is compressed to 10 ñ 0,5
bar.
Compressed air passes to the air dryer (3) where
moisture is removed as it flows through the dryer
dessicant. The dessicant in the lower portion of the
dryer becomes wet.
Dried air passes through a non-return valve NRV1 to
the reservoir (4).
The 3 non-return valves (6) ensure correct air flow.
They also prevent loss of spring pressure if total loss
of reservoir pressure occurs.
The pressure switch (5) maintains system pressure
between set limits by switching on and off the
compressor via an ECU controlled relay.For air to be admitted to an air spring (10), the inlet
valve (7) must be energised together with the relevant
air spring solenoid valve (9).
For air to be exhausted from an air spring, the exhaust
valve (8) must be energised together with the relevant
air spring solenoid valve.
The solenoid diaphragm valve (12) ensures that all air
exhausted to atmosphere passses through the dryer.
Exhausted air passes vertically downwards through
the dryer. This action purges moisture from the
dessicant and regenerates the air dryer.
Air is finally exhausted through the system air
operated diaphragm valve (13) and to atmosphere
through a silencer (14) mounted below the valve
block. 
						

							60FRONT SUSPENSION NEW RANGE ROVER
8
DESCRIPTION AND OPERATION FRONT SUSPENSION
Description
The front suspension design on the New Range Rover
allows maximum wheel travel and axle articulation,
providing good ground clearance without loss of
traction or directional stability.Near constant ride frequency under all load conditions
is achieved by utilizing advancements in suspension
geometry complemented to control and operation of
the air suspension system.
See this section.
Front axle suspension
1. Radius arms
2. Panhard rod
3. Shock absorbers
4. Bump stops
5. Anti-roll bar
6. Air springs
7. Front axle 
						

							ELECTRONIC AIR SUSPENSION
9
DESCRIPTION AND OPERATION Long front radius arms (1) are fitted to the front axle
(7) and provide maximum axle articulation which is
vital for off road performance. The radius arm,
comprising a forged steel link with twin front
mountings using ferrule rubber bushes, is secured to
fabricated mounting brackets welded to the front axle.
Flexible rubber bushes are used on a stem end joint
to secure the rear of the radius arm to a mounting on
the chassis cross member as shown in 60M7040. The
vehicle height sensors are also linked to the front
radius arms; for full details of the height settings.
See
this section.
A panhard rod (2), which ensures that the axle
remains centrally located, is fitted transversely and
also uses ferrule rubber bush mountings at both axle
and chassis locations. An anti-roll bar (5) is fitted to
the front axle to control body roll and directional
stability. Two rubber bearing bushes, with retaining
straps, secure the anti-roll bar to the front axle, while
ball jointed links, suspended from the chassis, support
the rear of the anti-roll bar.Conventional telescopic shock absorbers (3), used to
control body movement, are secured to fabricated
towers which are welded to the chassis. The upper
fixing uses a single retaining bolt passing through a
flexible rubber bush. The lower fixing of the shock
absorber comprises of a stem type mounting with two
flexible rubber bushes and support washers secured
to an axle mounting by a single retaining nut. Cellular
foam bump stops (4) are fitted under the chassis
adjacent to the air springs (6) and prevent possible
damage that could occur should there be excessive
axle to chassis movement. Should there be a loss of
air pressure in the air springs the vehicle can still be
driven safely at a speed not exeeding 35 mph (56kph)
with the bump stops resting on the axle, although this
will result in a hard ride. The loss of air pressure
should be investigated as soon as possible. The bump
stops are progressive and will reform from a
compressed state when the load is released. 
						

							SUPPLEMENTARY RESTRAINT SYSTEM
1
DESCRIPTION AND OPERATION SYSTEM COMPONENTS - DISTRIBUTED SRS
SYSTEM
1. Airbag crash sensors
2. SRS warning light (airbag)
3. Rotary coupler
4. Drivers airbag module
5. Passengers airbag module6. Airbag diagnostic socket
7. Airbag diagnostic control unit
8. Airbag harness 
						

							75SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER
2
DESCRIPTION AND OPERATION OPERATION
The airbag supplementary restraint system (SRS) is a
safety device which, when used in conjunction with
the seat belt, is designed to protect the driver and
front passenger by operating when the vehicle
receives a frontal impact (in the area shown)
exceeding a certain set speed.
In the event of a frontal impact, when the airbag
diagnostic control unit and one of the airbag crash
sensors senses the impact, the diagnostic control unit
triggers the airbag modules which fires an igniter. This
in turn ignites tablets of sodium azide which generate
a large amount of Nitrogen gas leading to airbag
inflation in approximately 30 milli-seconds.
When fully deployed the airbag offers additional
protection to the front seat occupant. As an occupant
moves into the airbag it immediately discharges the
gas from vent holes to provide progressive
deceleration and reduce risk of injuries. The whole
process is completed in approximately 0.3 seconds.
WARNING: All the airbag system
components, including the wiring harness,
MUST be renewed after the airbags have
deployed.SRS warning light (airbag)
The warning light in the instrument pack illuminates
after the electrical circuits are switched on whilst a
system check is carried out. After about 7 seconds the
warning light will go out. The system checks the
airbag diagnostic control unit, airbag crash sensors
and the airbag harness.
In the event of a fault in the system the warning light
will lluminate and begin modulating. The airbag
diagnostic control unit logs the fault which can only be
accessed usingTestBook. 
						

							SUPPLEMENTARY RESTRAINT SYSTEM
3
DESCRIPTION AND OPERATION SYSTEM COMPONENTS - SINGLE POINT SENSED
SRS SYSTEM
1. SRS warning light (airbag)
2. Rotary coupler
3. Drivers airbag module4. Passengers airbag module
5. Airbag diagnostic socket
6. Airbag diagnostic control unit (DCU)