Suspension - Revised Front Air Spring Removal Procedure
No: LM204-008Issue: 1
Date: 13 Nov 2006
SECTION: 204-01 - SUSPENSION SYSTEM
Front Air Spring Assembly Removal - Procedure Change
AFFECTED VEHICLE RANGE:
New Range Rover (LM) Model Years: 3A101029 onwards
CONDITION SUMMARY:
CHANGES TO THE PROCEDURE FOR REMOVAL AND INSTALLATION OF A FRONT AIR SPRING ASSEMBLY
Situation: Land Rover engineering has recently studied the service process for replacing the front air spring assembly for Range Rover (LM) models. Significant procedure changes have been made that refine and improve the process. The operation may now be carried out more efficiently. The procedure changes are as follows:
* Removal of the brake caliper is no longer required.
* Removal of the track rod end from the hub is no longer required.
NOTE: The relevant Work Shop Manual sections affected by these refined procedures will be updated at the next available opportunity.
Action: Should it become necessary to remove a front air spring assembly from a 2003-2005 MY Range Rover (LM), refer to the Service Procedure detailed in this bulletin. For 2006MY onward vehicles, refer to the updated Work Shop Manual - New Systems procedure available on GTR.
PARTS:
No parts required for this bulletin. Repair Procedure and labor time change information only.
WARRANTY:
NOTE: Superseded repair times and associated labor operations have changed as follows:
* Replace air spring assembly - one side (2003-2005 MY) - 60.21.01 was 1.10 hours.
* Replace air spring assembly - one side (2006 MY on) - 60.21.01 was 1.20 hours.
* Replace air spring assembly - both sides (2003-2005 MY) - 60.21.02 was 1.60 hours.
* Replace air spring assembly - both sides (2006 MY on) - 60.21.02 was 1.60 hours.
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.
Service Procedure
Please note that the relevant Workshop Manual Section, which these updated procedures relate to, will be updated at the next available opportunity.
Air spring assembly - one side - renew (60.21.01)
NOTE:Do not depressurize air suspension system before raising vehicle.
1. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. Raise the front and rear of the vehicle and support under the body.
2. Remove the road wheel.
3. Depressurize the air spring being replaced.
4. Release the anti-lock braking (ABS) sensor harness and brake hose from the damper.
5. Left-hand side only:
1. Release the brake pad wear sensor lead from the damper.
6. CAUTION: Use an open-ended wrench on the flats provided to prevent the ball joint rotating.
Remove the nut securing the stabilizer bar link to the damper.
7. Release the stabilizer bar link and collect the washer.
8. Position a jack to support the lower arm.
9. Remove the two nuts and bolts securing the hub to the damper.
10. CAUTION: Do not allow the hub to hang on the brake hose.
Release the hub from the damper and lower arm, sufficiently to clear the damper.
11. Remove the cap from the top mounting.
12. Remove the nut securing the spring and damper assembly and mark relationship between stud and turret for reference during reinstallation.
13. Remove the two remaining nuts; release the spring and damper assembly and lower sufficiently for access to the air pipe connection.
14. CAUTION: Install plugs to open connections to prevent contamination.
Disconnect the air pipe.
15. Remove the spring and damper assembly.
16. Remove and discard the paper gasket from the spring and damper assembly.
Install
17. Clean the spring and damper location.
18. If installing a new spring and damper assembly, remove the air connector blanking plug from the assembly.
19. Install a new paper gasket to the spring and damper assembly.
20. CAUTION: Ensure air pipe connections are clean.
Position the spring and damper assembly, connect the air pipe but do not tighten the union at this stage.
21. CAUTION:Ensure the paper tag on the gasket is visible through the large hole on suspension turret.
Locate the spring and damper assembly to the body, install the top mounting nuts, align the stud to the reference mark and tighten the nuts to 56 Nm.
22. Install the cap to the top mounting.
23. Tighten the air pipe connection to 3.5 Nm.
24. Connect the hub to damper, install the bolts and tighten to 250 Nm.
25. Secure the brake hose and ABS sensor harness to the damper.
26. Left-hand side only:
1. Secure the pad wear sensor lead.
27. Install the washer, connect the stabilizer bar link, install the nut and tighten to 100 Nm.
28. CAUTION: The system must be pressurized before lowering the vehicle on the suspension.
Pressurize the suspension.
29. Install the road wheel(s) and tighten nuts to 140 Nm.
30. Remove stand(s) and lower vehicle.
31. Check the front wheel alignment.
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