Suspension - Electronic Air Suspension Trouble Codes
No: LM204-002*Issue: 3*
Date: 24 Oct 2006
CHANGES MADE FOR ISSUE "3" ARE HIGHLIGHTED WITH GREY BACKGROUND AND ASTERISKS
SECTION: 204-05
Electronic Air Suspension Fault Codes
AFFECTED VEHICLE RANGE:
Range Rover (LM) VIN: 6A198056 to 6A222277
CONDITION SUMMARY:
ELECTRONIC AIR SUSPENSION (EAS) WARNING MESSAGE
Situation: A customer may report a warning message "Air Suspension Inactive" from the message center. Diagnosis using the Worldwide Diagnostic System (WDS) *or Integrated Diagnostic System (IDS)* reveals Diagnostic Trouble Code (DTC) C1A20-64 (pressure increases too slowly while filling reservoir) or C113192 (unable to pressurize gallery). No air leaks are found. At elevated temperatures the exhaust valve spring return force is not great enough to overcome friction. The compressor exhaust valve may stick or be damaged, causing an internal air leak when the compressor is active.
*Action: Should a customer express concern regarding the above, refer to the Repair Procedure detailed in this bulletin to repair the air compressor using a delivery valve/exhaust valve repair kit and update the air suspension Ride Level Control Module software. Compressor replacement will only be required in rare circumstances as specified in the Repair Procedure.*
PARTS:
* JPO500010..............Compressor repair kit Qty 1
RQG500100.............Air compressor assembly Qty 1 If determined by inspection*
TOOLS:
WDS Diagnostic Disc.........CD13 or later
IDS Diagnostic Disc............DVD100 or later
303-D121 ........................Puller (modified to two leg condition) 303-588............................Protective button from this tool
WARRANTY:
NOTE: Repair procedures are under constant review, and therefore times are subject to change; those quoted here must be taken as guidance only. Always refer to DDW to obtain the latest repair time.
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
AIR LEAK INSPECTION
1. Verify no air leaks are found at any of the following locations:
^ Compressor
^ Reservoir solenoid valve block
^ Reservoir
^ Front solenoid valve block
^ Rear solenoid valve block
^ Intermediate connections and pipe work
*ALL COMPRESSOR REPAIR PROCEDURES IN ISSUE "3" ARE NEW INFORMATION*
INSPECT AIR COMPRESSOR
NOTE: GTR lookup sequence is as follows: GTR Home > NAS > Service Information/ LM-New Range Rover/2006 > Workshop Manuals > Range Rover-Workshop Manual-New Systems > Bookmark "Chassis / Suspension / 204-05 Vehicle Dynamic Suspension > Link "Air Suspension Compressor (60.50.10)"
NOTE: The part number can be a stamped number, a self-adhesive label carrying the part number or it may be written with a paint-pen.
1. Remove the load space floor panel, spare wheel and compressor cover to expose the compressor.
2. Check the part number of the compressor located on the front cover of the compressor assembly. (Figure 1)
3. Refer to the table below and determine the action required from the observed compressor part number.
NOTE: GTR lookup sequence is as follows: GTR Home > NAS > Service Information/ LM - Range Rover /2006> Workshop Manual New Systems > Bookmark "Suspension/ 204-05: " Link: General Procedures - "Air Suspension System Depressurize and Pressurize (60.50.38)"
WARNING: A small amount of air pressure will be left in the air suspension system. Eye protection must be worn.
4. Depressurize the air suspension.
CAUTION: Cleaning the area around the delivery valve-retaining plug will help prevent contamination.
5. Clean the area around the delivery valve-retaining plug.
6. Undo and remove the delivery valve-retaining plug. (Figure 2)
7. Remove and discard the plug O-ring seal.
8. Remove the return spring and the delivery valve.
9. Discard the spring.
10. Inspect the delivery valve for damage:
11. If the valve is damaged (Figure 3), perform the step that applies:
* If the air compressor part number is RQG500040 replace the air compressor.
* If the air compressor part number is RQG500041 perform the Compressor Rework Procedure below.
12. If the valve is not damaged (Figure 3) or the compressor has part number RQG500041, perform the Compressor Rework Procedure.
COMPRESSOR REWORK PROCEDURE
1. Install a new O-ring seal to the delivery valve-retaining plug.
2. Assemble the new spring and new delivery valve.
3. Tighten the delivery valve-retaining plug to 12.5 Nm (9.2 lbf.ft).
CAUTION: Clean the area around the valve plunger cover to prevent contamination.
4. Undo, remove and discard the two exhaust valve plunger cover securing screws to allow puller to be installed. (Figure 4)
5. Configure special tool 303-D121 to two-leg mode or alternatively, use a suitable two-leg puller. (Figure 5)
6. Install and align special tool 303-D121 and the protective button from tool 303-588 to the exhaust valve plunger cover.
7. Hand-tighten puller screw to hold plunger cover in position. (Figure 6)
8. Undo, remove and discard the remaining plunger cover securing screws. (Figure 6)
9. Clean area around each screw hole using a vacuum cleaner, to prevent debris from entering the plunger chamber.
10. Carefully back-off the puller, allowing even reduction in cover spring pressure and remove the tool.
11. Remove the cover.
12. Clean area around each screw hole using a vacuum cleaner, to prevent debris from entering the plunger chamber.
13. Remove and discard the orange O-ring seal.
14. Install the new inner spring and spacer at the center of the original outer spring. (Figure 7)
15. Install and fully seat the new orange O-ring seal. (Arrowed in Figure 7)
16. Install and align the plunger cover.
17. Install the puller and protective button.
18. Tighten tool by hand to compress springs, ensuring the cover is clamped evenly.
CAUTION: Care must be exercised to avoid cross-threading the new screws being installed. Proper installation is best performed by positioning the screw in the hole, rotating the screw counter-clockwise until a 'click' is heard and then rotating the screw clockwise by hand a minimum of two turns to engage the threads.
19. Install, but do not fully tighten, two new plunger cover securing screws into the exposed holes.
20. Undo and remove special tool 303-D121.
21. Install the two remaining new plunger cover screws and tighten to 5 Nm (3.6 lbf.ft).
22. Final tighten the first two screws to 5 Nm (3.6 lbf.ft).
23. Using a suitable paint marker, strike through the original part number on the compressor to identify that the unit has been reworked.
24. Install the compressor cover, spare wheel and load space floor panel.
NOTE: The ride level control module will require the latest calibration. This will be downloaded during the control module technology upgrade process (B036) detailed in this Bulletin.
NOTE: Following rework/replacement of the compressor there is no requirement to recalibrate the air suspension ride height.
25. Refer to GTR Workshop Manual section 60.50.38 and pressurize the air suspension.
INSTALL LATEST EAS SOFTWARE
NOTE: A Midtronics PSC-550 Vehicle Power Supply must be connected to the vehicle battery during diagnosis and module configuration.
1. Connect the diagnostic equipment to the vehicle and begin a WDS/IDS session.
2. Determine the current software levels of the Ride Level Control Module as follows:
^ Enter the vehicle details.
^ When prompted "Do you wish to read trouble codes?" select "NO" and press the tick-box to continue.
^ Select the 'Vehicle Configuration' tab.
^ Select 'Module Information'.
^ Select 'Network Integrity Test'.
^ Note the software part numbers displayed on the screen.
NOTE: Following software download, it is not necessary to re-calibrate the suspension ride height.
3. Configure the Ride Level Control Module software as follows:
^ Return to the 'Vehicle Configuration' screen and select 'Module Configuration'.
^ Check the software part number displayed on WDS/IDS screen is different than the software part number noted in Step 2 'Module Information' above.
^ If software part numbers are the same, discontinue tune down load and proceed to Step 6.
^ Select 'Configure Existing Modules'.
^ Select 'Ride Level Control Module' from the sub-menu.
^ Check the tick-box to continue and follow the on-screen instructions.
4. Repeat Step 2 to confirm the software level change.
5. Exit the WDS/IDS session and disconnect the diagnostic equipment from the vehicle.
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