Range Rover Classic. Manual — part 119
68
AIR SUSPENSION
4
REPAIR
FRONT DAMPER
Service repair no - 60.30.02
Remove
WARNING: Air suspension is pressurised
up to 10 bar. Dirt or grease must not enter
the system. Wear hand, ear and eye safety
standard protection when servicing system.
WARNING: Unrestricted movement of a
pressurised air spring will result in failure
of assembly, causing component damage
and possible personal injury. It is possible to
remove damper assembly without depressurising
air springs, providing distance between axle and
chassis is held as if damper assembly were still
fitted. This is achieved by supporting vehicle on
stands with a jack under the axle.
1. Disconnect battery negative lead.
2. Remove wheel.
See WHEELS AND TYRES,
Repair, Wheels
3. Support chassis on axle stands.
4. Support front axle with jack.
CAUTION: Do not lower axle when damper
is removed, this may result in damage to
air springs.
5. Remove top and bottom damper fixings.
6. Remove damper.
Refit
7. Fit damper.
8. Fit top and bottom fixings, ensuring mounting
rubbers are fitted as shown.
9. Tighten fixings to
38Nm.
10. Reverse removal procedure. 1 to 4.
AIR SUSPENSION
5
REPAIR
REAR DAMPER
Service repair no - 64.31.02
Remove
WARNING: Air suspension is pressurised
up to 10 bar. Dirt or grease must not enter
the system. Wear hand, ear and eye safety
standard protection when servicing system.
WARNING: Unrestricted movement of
pressurised air spring will result in failure
of assembly, causing component damage
and possible personal injury. It is possible to
remove damper assembly without depressurising
air springs, providing distance between axle and
chassis is held as if damper assembly were still
fitted. This is achieved by supporting vehicle on
stands with a jack under the axle.
1. Disconnect battery negative lead.
2. Remove wheel.
See WHEELS AND TYRES,
Repair, Wheels
3. Support chassis on stands.
4. Support axle with jack.
CAUTION: Do not lower axle when damper
is removed, this may result in damage to
air springs.
5. Remove damper top and bottom fixings.
6. Remove damper.
Refit
7. Fit damper.
8. Fit top fixings. Tighten to
82Nm.
9. Fit bottom fixings, ensure mounting rubbers are
fitted as shown. Tighten to
38Nm.
10. Reverse removal procedure. 1 to 4.
68
AIR SUSPENSION
6
REPAIR
FRONT AIR SPRING
Service repair no - 60.21.01
Remove
WARNING: Air suspension is pressurised
up to 10 bar. Dirt or grease must not enter
the system. Wear hand, ear and eye safety
standard protection when servicing system.
WARNING: The air spring must be
restricted by suspension loading, with
dampers fitted before inflation. Failure to
observe this warning could cause air spring
failure, resulting in component damage or
personal injury. DO NOT ATTEMPT TO
DISMANTLE AIR SPRING
1. Depressurise system.
See Adjustment,
Depressurise System
2. Disconnect battery negative lead.
3. Remove wheel,
See WHEELS AND TYRES,
Repair, Wheels
4. Support chassis on axle stands.
5. Support front axle with jack.
6. Peel back rubber boot. Disconnect air pipe from
air spring.
See Disconnect/Connect Air Pipe
7. Remove four retaining clips from upper and
lower fixing.
8. Remove air spring assembly.
Refit
9. Locate air spring assembly onto lower fixing,
ensure air pipe connection points rearwards.
10. Connect air pipe to air spring assembly.
See
Disconnect/Connect Air Pipe
11. Raise axle to locate air spring assembly into
upper fixing, if required.
12. Fit new retaining clips to fixing points.
13. Reverse removal instructions 1 to 6.
14. Leak test air spring and around connections.
See Adjustment, Leak Test Procedure
REAR AIR SPRING ASSEMBLY
Service repair no - 64.21.01
Remove
WARNING: Air suspension is pressurised
up to 10 bar. Dirt or grease must not enter
the system. Wear hand, ear and eye safety
standard protection when servicing system.
WARNING: The air spring must be
restricted by suspension loading, with
dampers fitted before inflation. Failure to
observe this warning could cause air spring
failure, resulting in component damage or
personal injury. DO NOT ATTEMPT TO
DISMANTLE AIR SPRING
1. Depressurise system.
See Adjustment,
Depressurise System
2. Disconnect battery negative lead.
3. Remove wheel,
See WHEELS AND TYRES,
Repair, Wheels
4. Support chassis on axle stands.
5. Support axle with jack.
AIR SUSPENSION
7
REPAIR
6. Remove four retaining clips from upper and
lower fixing.
7. Lower axle for access to air pipe connection at
top of air spring.
8. Clean connection with a stiff brush and soapy
water. Peel back rubber boot.
9. Disconnect air pipe.
See Disconnect/Connect
Air Pipe , seal all ends.
10. Remove air spring assembly.
Refit
11. Locate air spring assembly onto lower fixing.
Ensure air pipe connection points towards rear.
12. Connect air pipe to air spring assembly, fitting
rubber boot.
See Disconnect/Connect Air
Pipe
13. Raise axle to locate air spring assembly into
upper fixing, if required.
14. Fit four new retaining clips to fixing points.
15. Reverse removal instructions 1 to 5.
16. Leak test air spring and connector.
See
Adjustment, Leak Test Procedure
BUMP STOP
Service repair no - 60.30.10
CAUTION: Air suspension system uses
’progressive’ bump stops, which must not
be interchanged with those used on coil
spring suspension.
Remove
1. Remove 2 locknuts and bolts with flat washers.
2. Remove bump stop assembly.
Refit
3. Position fixing bolts and flat washers in chassis
bracket.
4. Fit bump stop.
5. Tighten fixings.
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