Service Action - Vehicle Enhancement Program (SB036)

INSPECT AIR COMPRESSOR

1. Locate the air suspension compressor mounted on the left side frame rail and inspect the crank case end plate for the part number. (Fig 1)
2. Refer to the table below and determine the action required from the observed compressor part number.
   Fig 1: Identifying Crank Case End Plate Part Number

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   PART NUMBER
   
   

   Part Number	Action Required LR3 and Range Rover Sport
   RQG500080 RQG500090	Latest level compressor. No further action is required.
   RQG000017	Check delivery valve. If delivery valve is damaged, replace the air suspension compressor. If delivery valve is not  damaged, install a new delivery valve and install the exhaust valve kit.
   RQG000018
   RQG000019
   RQG500060
   RQG500061
   RQG500070
   RQG500071
   RQG500062	Install a new delivery valve and install the exhaust valve kit.
   RQG500072

   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. (Fig 2)
Fig 2: Locating Connections Of Inlet And Outlet Pipes
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5. Undo and remove the delivery valve-retaining plug: (Fig 3)
   Fig 3: View Of Delivery Valve

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   • 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 ( Fig 4)
Fig 4: Identifying Damaged Delivery Valve
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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 Fig 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 Fig 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)

1. Install new delivery valve assembly from kit JPO500010 as follows: (Fig 5)
   Fig 5: View Of Delivery Valve

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   • 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. (Fig 6)
Fig 6: Locating Exhaust Valve Plunger Cover Securing Screws
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3. Configure special tool 303-D121 to two-leg mode or alternatively, use a suitable two-leg puller. (Fig 7)
Fig 7: Identifying Special Tool
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4. Install and align special tool 303-D121 and the protective button from tool 303-588 to the exhaust valve plunger cover. (Fig 8)
Fig 8: Installing Special Tool
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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. (Fig 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 Fig 9)
Fig 9: Identifying O-ring Seal
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11. Install the new inner spring and spacer from kit JPO500010 at the center of the original outer spring. (Fig 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. (Fig 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.
Fig 10: Installing Special Tool
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15. Install and finger tighten the two exposed cover screws to secure the cover. (Fig 10)
16. Undo and remove special tool 303-D121.
17. Install the two remaining new plunger cover screws. (Fig 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.
    Fig 11: Locating Exhaust Valve Plunger Cover Securing Screws

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INSPECT AIR COMPRESSOR

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. (Fig 12)
3. Refer to the table below and determine the action required from the observed compressor part number.
   Fig 12: Locating Part Number

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   PART NUMBER
   
   

   Part Number	Action Required Range Rover
   RQG500100	Latest level compressor. No further action is required.
   RQG500040	Check delivery valve. If delivery valve is damaged, replace the air suspension compressor. If delivery valve is not  damaged, install a new delivery valve and install the exhaust valve kit.
   RQG500041	Install a new delivery valve and install the exhaust valve kit.

   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. (Fig 13)
7. Remove and discard the plug O-ring seal.
8. Remove the return spring and the delivery valve.
9. Discard the spring.
   Fig 13: View Of Delivery Valve-Retaining Plug

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10. Inspect the delivery valve for damage:
11. If the valve is damaged (Fig 14), perform the step that applies:
    Fig 14: Identifying Damaged Delivery Valve

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    • 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 (Fig 14) or the compressor has part number RQG500041, perform the COMPRESSOR REWORK PROCEDURE.

COMPRESSOR REWORK PROCEDURE (RANGE ROVER)

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 12.5Nm (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. (Fig 15)
Fig 15: Removing Exhaust Valve Plunger Cover
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5. Configure special tool 303-D121 to two-leg mode or alternatively, use a suitable two-leg puller. (Fig 16)
   Fig 16: Identifying Special Tool

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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. (Fig 17)
Fig 17: Pulling Plunger Cover
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8. Undo, remove and discard the remaining plunger cover securing screws. (Fig 17)
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. (Fig 18)
Fig 18: Installing Inner Spring And Spacer
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15. Install and fully seat the new orange O-ring seal. (Arrowed in Fig 18)
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 5Nm (3.6 lbf.ft)  .
22. Final tighten the first two screws to 5Nm (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.

2006 RANGE ROVER (LM) VEHICLES ARE NOW COVERED BY THE CAMPAIGN 

CONTROL MODULE TECHNOLOGY UPGRADE PROCESS

LR3 (LA) VIN 5A000259 to 6A390949 

Range Rover Sport (LS) VIN 6A900109 to 6A956539 

Range Rover (LM) VIN 6A192814 to 6A235003 

1. Verify the correct minimum level of IDS software is installed for the vehicle being updated:
   RANGE ROVER SPECIFICATION
   
   

   LR3 or Range Rover Sport	IDS DVD104 - Patch File 2 or later installed
   Range Rover	IDS DVD 104 - Patch File 2 or later installed

2. If the correct software level is installed go to step  5.
   NOTE: The software patch installation help file provides instructions for the patch file installation process and could take up to 6 minutes to download dependent on connection speed.
3. If the correct Patch Files has not  been installed or is unknown, download the IDS software patch installation help file from GTR as follows:
   • Logon to GTR,
   • Select 'Home' from the menu at the top of the main page.
   • From the menus on the left of the page, select 'Diagnostics' as the 'Information Type' and select the relevant model and model year.
   • From the 'All Information' results, select 'Patch Files'.
   • Click the file link 'Patch Process Help File'.
   NOTE: The patch file download process could take up to 20 minutes to download dependent on connection speed.
4. Using the help file, follow the instructions to download and install the software patch file into IDS and ensure IDS successfully restarts.
   CAUTION: Midtronics PSC550 vehicle power supply must be connected to the vehicle battery during diagnosis/module configuration.
   CAUTION: The diagnostic lead must be correctly secured and cannot be accidentally disconnected during software update.
5. Connect the Midtronics PSC550 vehicle power supply device and the diagnostic equipment to the vehicle.
6. Begin an IDS session.
7. Follow the on-screen prompts and enter the vehicle VIN.
8. Wait while the vehicle configuration file (CCF) uploads.
9. Select the 'Vehicle Configuration' tab and select 'Module Programming' from the menu.
10. Select 'Configure Existing Modules'.
11. Navigate to the bottom of the existing module list and select "Reassurance Programme" to display the submenu of specific modules for this campaign.
    NOTE: When "Reassurance Programme" is selected, a list of control units will appear that are to be programmed as part of this procedure. Each of these control units must be programmed in sequence to complete the requirements of Service Action B036.
    CAUTION: For current Land Rover vehicles the automatic transmission internal temperature must be less than  176°F (80°C) prior to initiating programming of the TCM. If the temperature is above the limit, IDS will display either "No Software Available For This Variant" or "Unspecified Error Has Occurred" depending on vehicle configuration. If either of these messages displays the likely cause is transmission temperature. The transmission must cool before the software update can be completed. Transmission temperature can be viewed using the IDS Datalogger.
12. Refer to the attached "Reassurance Programme Form"  . Select and program the modules in the order shown on the Reassurance Program sub-menu.
13. While waiting for the software upgrade processes to complete, perform the following on LR3 vehicles:
    • Inspect E-Box sealing grommet on LR3 vehicles between VIN 5A000259 and 6A390949:
      • Open the hood and install fender protection covers.
      • Inspect the E-Box grommet for proper location and seal. (Fig 2)
      • If located correctly, no further action is required.
      • If repair is required wait  until downloads are complete.
    • Perform "UPPER TAILGATE SUPPORT BALL STUD RATTLE REPAIR " below on LR3 vehicles between VIN 5A000259 and 6A374836.
14. When downloads are complete, exit the WDS/IDS session and disconnect the diagnostic equipment from the vehicle.

UPPER TAILGATE SUPPORT BALL STUD RATTLE REPAIR

LR3 (LA) VIN: 5A000259 to 6A374836 

1. Release the upper tailgate support strut from the D-pillar ball stud. (Fig 19)
Fig 19: Removing Upper Tailgate Support Strut From D-Pillar Ball Stud
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2. Remove the ball stud assembly from the body.
3. Apply liquid thread-lock (STC50552/Loctite 242) to the ball spigot thread.
4. Install the ball spigot.
5. Tighten to 23Nm (17 lbf.ft)  .
6. Install the upper tailgate support.

ENVIRONMENTAL BOX (E-BOX) SEALING GROMMET

LR3 (LA) VIN: 5A000259 to 6A374589 

1. If the E-box grommet was determined to not be located correctly during the inspection above, perform the following:
   • Disconnect and remove the battery for access.
   • Install the grommet. (Fig 20)
   • Install the battery and connect battery leads.
2. Remove fender protection covers, and close the hood.
   Fig 20: Installing Grommet

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SOFTWARE UPDATE INSTRUCTIONS

Fig 21: Software Update Instructions

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Fig 22: Reassurance Program Form

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Fig 23: Monitor Trace Procedure (Page 1 Of 9)

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Fig 24: Monitor Trace Procedure (Page 2 Of 9)

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Fig 25: Monitor Trace Procedure (Page 3 Of 9)

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Fig 26: Monitor Trace Procedure (Page 4 Of 9)

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Fig 27: Monitor Trace Procedure (Page 5 Of 9)

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Fig 28: Monitor Trace Procedure (Page 6 Of 9)

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Fig 29: Monitor Trace Procedure (Page 7 Of 9)

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Fig 30: Monitor Trace Procedure (Page 8 Of 9)

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Fig 31: Monitor Trace Procedure (Page 9 Of 9)

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