Part 1
B034 - Air Suspension Compressor RepairAFFECTED VEHICLE RANGE:
Land Rover LR3 (LA) VIN: 5A000259 to 6A374589
Range Rover Sport (LS) VIN: 6A900109 to 6A937698
*Range Rover (LM) VIN: 6A198058 to 6A222277*
CONDITION SUMMARY
Situation: Air compressors for the Electronic Air Suspension systems have undergone continual improvement. To ensure that compressors are updated to the latest configuration an inspection and repair process is being undertaken as part of this Service Action.
Action: At the earliest Service opportunity check and note the part number located on the compressor crank case end plate of the air suspension compressor. Determine what repair action is required from the part number and the information in the Repair Procedure.
NOTE: At the time of confirming a booking for vehicle repair, please ensure that all outstanding Field Service Actions are identified to ensure the correct parts are available and adequate workshop time is allocated for repairs to be completed at one visit.
TOOLS:
303-D121.................Puller (modified to two leg condition)
303-588....................Protective button from this tool
PARTS:
JPO500010..............Compressor kit - includes delivery valve and exhaust valve kit Qty 1
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.
NOTE: In the unlikely event that compressor replacement is necessary, make a separate warranty claim for the replacement PART ONLY using the normal process. The labor cost to renew the compressor will be covered under the terms of this Service Action. Claim Option E.
Warranty claims should be submitted quoting program code B034 together with the relevant option code from the table below. This will result in payment of the stated time. As option codes are used, there is no requirement for you to enter SRO or relevant parts information; they are repeated here for information only. The option that allows for the drive in/drive out allowance can only be claimed if the vehicle is brought back into the workshop for this action alone to be undertaken
Normal warranty policy and procedures apply.
COMPRESSOR REPAIR PROCEDURE LR3 AND RANGE ROVER SPORT
INSPECT AIR COMPRESSOR
NOTE: The part number can be a stamped number, a self-adhesive label carrying the new part number or it may be written with a paint-pen.
1. Locate the air suspension compressor mounted on the left side frame rail and inspect the crank case end plate for the part number. (Figure 1)
2. 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/ LS - Range Rover Sport/2006 or LA - LR3/2005 > Workshop Manuals > Bookmark "Suspension/ 204-05: " Link "Air Suspension Compressor (60.50.10)"
3. If the compressor part number is anything other than RQG500080 or RQG500090, remove the air suspension compressor from the vehicle.
CAUTION: Plugs installed in the open connection locations are required to prevent contamination.
4. Install plugs to the open connections of the inlet and outlet pipes of the compressor being inspected and clean the compressor assembly. (Figure 2)
5. Undo and remove the delivery valve-retaining plug: (Figure 3)
^ Remove and discard the retaining plug O-ring seal.
^ Remove the return spring and the delivery valve and discard the spring.
^ Inspect the delivery valve for damage (Figure 4)
6. If the compressor has part number RQG000017, RQG000018, RQG000019, RQG500060, RQG500061, RQG500070 or RQG500071 select the proper repair as follows:
^ If the delivery valve is damaged (left image in Figure 4) replace the air compressor with a new unit following GTR section 60.50.10 procedures.
^ If the delivery valve is not damaged, (right image in Figure 4) perform the Compressor Repair Procedure that follows.
7. If the compressor part number is RQG500062 or RQG500072 or if the delivery valve is not damaged in the above inspection, perform the Compressor Repair Procedure that follows.
COMPRESSOR REPAIR PROCEDURE (LR3, RANGE ROVER SPORT)
NOTE: This repair procedure only applies to a compressor that meets the following criteria:
^ Part number RQG000017, RQG000018, RQG000019, RQG500060 RQG500061 RQG500070 or RQG500071 that upon inspection have an undamaged delivery valve.
^ Part number RQG500062 or RQG500072.
1. Install new delivery valve assembly from kit JPO500010 as follows: (Figure 5)
^ Install a new O-ring seal to the delivery valve-retaining plug.
^ Assemble the new spring and new delivery valve.
^ Install new spring and new delivery valve into the compressor.
^ Tighten the delivery valve-retaining plug to 12.5Nm (9.2 lbf.ft).
2. Undo, remove and discard two diagonally opposed exhaust valve plunger cover securing screws to permit puller installation. (Figure 6)
3. Configure special tool 303-D121 to two-leg mode or alternatively, use a suitable two-leg puller. (Figure 7)
4. Install and align special tool 303-D121 and the protective button from tool 303-588 to the exhaust valve plunger cover. (Figure 8)
5. Hand tighten the tool only enough to hold the plate in position.
6. Undo, remove and discard the two remaining plunger cover securing screws. (Figure 8)
7. Clean area around each screw hole using a vacuum cleaner to prevent debris from entering the plunger chamber.
8. Carefully back off the puller, allowing even reduction in the cover spring pressure.
9. Remove the cover when spring tension is relaxed.
10. Remove and discard the orange O-ring seal. (Arrowed in Figure 9)
11. Install the new inner spring and spacer from kit JPO500010 at the center of the original outer spring. (Figure 9)
12. Install and fully seat the new orange O-ring seal from kit JPO500010.
13. Install and align the plunger cover.
CAUTION: The cover must be positioned and clamped evenly during the following step.
14. Install the puller and the "button" special tool and carefully tighten the puller to compress the springs to a snug seated condition. (Figure 10)
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.
15. Install and finger tighten the two exposed cover screws to secure the cover. (Figure 10)
16. Undo and remove special tool 303-D121.
17. Install the two remaining new plunger cover screws. (Figure 11)
18. Tighten the final two screws to 5Nm (3.6 lbf.ft).
19. Tighten the first two screws installed to 5Nm (3.6 lbf.ft).
20. Using a suitable paint marker, strike through the original part number on the compressor to identify that the unit has been repaired.
21. Refer to GTR section 60.50.10 and install the repaired compressor unit to the vehicle.
REPAIR PROCEDURE RANGE ROVER 6A198058 TO 6A222277
* THIS ENTIRE RANGE ROVER COMPRESSOR REPAIR SECTION IS NEW FOR ISSUE 5.
THE SECTION CONTENT IS NOT HIGHLIGHTED WITH GREY BACKGROUND:
INSPECT AIR COMPRESSOR
NOTE: GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LM - Range Rover /2006> Workshop Manual New Systems > Bookmark "Chassis/Suspension / 204-05 Vehicle Dynamic Suspension: " Link "Air Suspension Compressor (60.50.10)"
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.