3. Install the coolant expansion tank cap. 2010 Land Rover Range Rover (LM) V8-5.0L Technical Service Bulletin # TECLTB000574 Date: 080625

3. Install the coolant expansion tank cap. 2010 Land Rover Range Rover (LM) V8-5.0L Technical Service Bulletin # TECLTB000574 Date: 080625

Suspension - Warning Lamp ON/Multiple Codes Set

No.: LTB00057

Issue: 4

Date: 25 June 2008

ISSUE '4' CHANGES ARE HIGHLIGHTED IN GRAY, AND SHOWN WITH ASTERISKS.

SECTION: 204-00

Suspension Warning Lamp Illuminated - Diagnostic and Repair Procedure

AFFECTED VEHICLE RANGE:

Range Rover Sport (LS) VIN: 6A901924 - Onwards

Model Year: 2006 - Onwards

CONDITION SUMMARY:

RED SUSPENSION WARNING LAMP ILLUMINATED ON INSTRUMENT CLUSTER

Situation:

The customer may complain that the suspension red warning lamp is illuminated on the instrument cluster. Upon diagnosis all or some of the

Diagnostic Trouble Codes (DTC) C1119 62, C1119 09 and C1B 1162 may be stored, possibly indicating system contamination.

Action:

This Technical Bulletin provides a process for Retailers to correctly diagnose Dynamic Response system contamination, to identify if an actuator has

failed and to determine which parts may require replacement. A flushing procedure is provided which will enable the dealer to clean the affected

parts that do not need to be replaced and ensure that the problem does not re-occur. Should a customer express concern, use IDS to establish which

actuator is at fault, and carry out the flush and repair procedure following the Repair Procedure outlined below.

PARTS

TOOLS

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WARRANTY

Diagnostic Procedure

DIAGNOSTIC PROCEDURE

CAUTION:

A Midtronics PSC-550 Vehicle Power Supply must be connected to the vehicle battery during diagnosis.

1. Connect the Midtronics PSC-550 Vehicle Power Supply to the vehicle battery.

2. Connect IDS to the vehicle and begin a new diagnostic session, by entering the correct VIN for the current vehicle.

3. Read and record diagnostic trouble codes.

NOTE:

This procedure must be followed if any of the following codes are present: C1119 62, C1119 09, C1B 1162.

CAUTION:

If the dynamic response reservoir is empty, pump damage is likely to have occurred.

4. Check the dynamic response fluid level.

WARNING:

Whenever working under a vehicle the vehicle must be supported with safety stands.

NOTE:

Global Technical Reference (GTR) lookup sequence is as follows:

GTR Home > NAS > LS Range Rover Sport > Service Information/ 2007 > Workshop Manuals > Bookmark "Body and Paint/501-02

2010 Land Rover Range Rover (LM) V8-5.0L Page 142

Front End Body Panels" LINK "Engine Undershield (76.10.50)"

5. If the fluid is low perform the following system inspection for leaks:

^ Raise and support the vehicle.

^ Refer to GTR Section 501-02 and remove the engine shield.

^ Remove the radiator access panel. (Figure 1)

^ Remove the right-hand (RH) splash shield. (Figure 2)

^ Inspect the dynamic response system for leaks.

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6. If the fluid level is correct, use IDS to perform the following diagnostic response system test:

^ Select 'Special Applications'.

^ Select 'Dynamic Response Hydraulic Control - System Test'.

^ Demand 50 bar (725 psi) of pressure for up to five minutes or until the primary circuit pipes are hot. ([A] in Figure 3)

^ Check pipe temperature under RH wheel arch.

^ If 50 bar (725 psi) cannot be obtained, * refer to GTR Workshop Manual section 204-06 (60.60.23) to replace the faulty Pressure Control

Valve (PCV) in the valve block*.

^ Open DCV1 and verify that system pressure is still 50 bar (725 psi).

^ Hold 50 bar (725 psi) pressure for two minutes.

^ If pressure has dropped by over 5 bar (72.5 psi), confirm in step 7 and replace the affected actuator.

^ Open DCV2 and verify that system pressure is still 50 bar (725 psi).

^ Hold 50 bar (725 psi) pressure for two minutes.

^ If pressure has dropped by over 5 bar (72.5 psi), confirm in step 7. The affected actuator will be replaced.

NOTE:

If the temperature comparison test is not conclusive at this stage, continued diagnosis revealing filter contamination (Condition B Figure 6)

may indicate that the front actuator requires replacement.

7. Confirm which actuator is faulty by observing the follow symptoms:

^ If all four pipes in the front wheel arch area are hot and at a similar temperature the front actuator is faulty.

^ If the pipes in the rear wheel arch are hot, the rear actuator is faulty.

^ If the pressure has dropped, but there is no increase in the actuator pipes and rear pipes temperature ([B] in Figure 3), the valve block is

faulty and requires replacement.

Check System Contamination and Replace Components As Required

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CHECK SYSTEM CONTAMINATION AND REPLACE COMPONENTS AS REQUIRED

1. Remove the reservoir filter to inspect for signs of debris as follows:

^ Release the dynamic response reservoir clip and tie the reservoir aside. (Figure 4)

^ Disconnect the intake air resonator.

^ Disconnect the RH mass air flow (MAF) sensor electrical connectors. (Figure 5)

^ Remove the RH air cleaner assembly.

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NOTE:

Some fluid spillage is inevitable during the reservoir removal operation.

^ Position container to collect fluid loss.

CAUTION:

Clean working conditions are critical before disconnecting or removing the components.

^ The area around the joint faces and connections must be cleaned and kept clean during work.

^ Open connections must be plugged to prevent contamination.

^ Remove the fluid reservoir as follows:

^ Clamp the hoses with hose pliers to prevent air ingress.

^ Release the two hose clamps.

^ Disconnect the hoses from the fluid reservoir.

NOTE:

Filter contamination can provide guidance for system troubleshooting and repair:

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^ A small number of random particles is acceptable ([A] in Figure 6).

^ If the filter is heavily contaminated with black particles and sludge ([B] in Figure 6), an actuator internal piston seal failure has probably

occurred.

^ If the filter is lightly contaminated with grey metallic looking particles ([C] in Figure 6), a pump failure may have occurred.

2. Inspect the reservoir fluid filter for signs of contamination.

^ If condition A is present no action is required.

^ If condition B is present, discard the reservoir and continue inspection and diagnosis from step 6 below.

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^ If condition C is present, discard the reservoir and continue inspection and diagnosis from step 5 below.

NOTE:

Global Technical Reference (GTR) lookup sequence is as follows:

GTR Home > NAS > LS Range Rover Sport> Service Information/ 2007 > Workshop Manuals > Bookmark "Chassis/204-06 Ride and

Handling Optimization" LINK "Valve Block (60.60.20)"

3. If indicated in "Diagnostic Procedure" Step 7, refer to GTR section 204-06 to install a new valve block.

4. If a valve block replacement is not indicated in "Diagnostic Procedure" Step 7, refer to GTR Workshop Manual, section: 204-06 (60.60.21) to

inspect the valve block filter as follows:

^ Remove the valve block filter.

^ Inspect the filter for signs of distortion or discoloration indicating excessive system pressure. (X in Figure 7)

^ Replace a distorted or discolored filter.

NOTE:

It will not be necessary to change either actuator if the pump is replaced.

5. If indicated by filter inspection in step 2, install a new dynamic response pump.

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2010 Land Rover Range Rover (LM) V8-5.0L Page 149

6. Inspect the high-pressure hose crimps for signs of crimp connector movement or excessive gap. (Figures 8 and 9)

7. Replace a hose assembly that shows signs of movement or a gap larger than 1 mm.

8. Install the new or inspected fluid reservoir as follows:

^ Clean the component mating faces.

^ Connect the hoses.

^ Install the hose clamps.

^ Remove hose pliers used to seal the hoses.

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NOTE:

When installing the air cleaner, make sure the locating pegs fit securely into the grommets.

9. Install the air cleaner assembly.

System Flush and Operational Check

SYSTEM FLUSH AND OPERATIONAL CHECK

NOTE:

It is not necessary to perform Step 1 below if the valve block or pump has been replaced.

1. Remove contaminated fluid from an actuator not diagnosed as faulty (without an internal leak) as follows:

^ Remove both wheels and tires.

^ Disconnect both the stabilizer bar links from the stabilizer bar.

^ Disconnect the dynamic response fluid pipes from the actuator.

NOTE:

Full movement in both directions of each arm must be performed to ensure fluid from both sides of the piston is removed.

CAUTION:

Fluid will be expelled when the actuator arms are moved.

^ Position a container to catch expelled fluid and move the actuator bar arms in opposite directions to displace the fluid.

2. Completely fill the reservoir with fluid.

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3. Connect the special system fluid refill tool (204-591-01) to the dynamic response reservoir.

4. Make sure the pressure regulator on the special tool is turned 'OFF'.

5. Fill the special tool bottle approximately three-quarters full with fluid.

6. Connect the special tool to a suitable workshop air supply.

WARNING:

Whenever working under a vehicle the vehicle must be supported with safety stands.

7. Raise and support the vehicle.

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8. Disconnect the two valve block actuator control valve electrical connectors. (Figure 11)

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9. Connect the special tool (204-591-02) electrical connectors to the valve block. (Figure 12)

10. Connect the special tool (204-591-02) power supply leads to the vehicle battery.

NOTE:

The O-ring seals are to be reused unless damaged.

11. Flush the front set of pipes as follows:

^ Disconnect the dynamic response fluid pipes from the actuator.

^ Using the special tool, open both actuator control valves.

^ Flush fluid through the front pipes until approximately 0.5 liter has been displaced.

^ Connect the fluid lines to the actuator and tighten the two bolts to 22 Nm (16 lbf ft).

12. Flush the rear set of pipes as follows:

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^ If the pipes have not been disconnected during step 1 of this section, disconnect the dynamic response fluid pipes from the actuator.

^ Flush fluid through the actuator until approximately 0.5 liter has been displaced.

^ Connect the fluid lines to the actuator and tighten the two bolts to 22 Nm (16 lbf ft).

NOTE:

It will not be necessary to replace any actuator if the pump has been replaced.

NOTE:

Global Technical Reference (GTR) lookup sequence is as follows:

GTR Home > NAS > LS Range Rover Sport> Service Information/ 2007 > Workshop Manuals > Bookmark "Chassis/204-06 Ride and

Handling Optimization"

13. If an actuator has been shown to be faulty in the diagnostic steps, refer to GTR Workshop Manual, section 204-06 (60.60.50 or 64.60.50) to

install a new actuator / stabilizer bar assembly.

14. Refer to GTR Workshop Manual section 204-06 (60.60.13) and bleed the dynamic response system.

15. Check and top-up the dynamic response system fluid reservoir to mid-way between the 'MAX' and 'MIN' marks.

16. Install the radiator access panel.

17. Tighten the bolts to 10 Nm (7.4 lbf ft).

18. Install the RH splash shield.

19. Refer to GTR Workshop Manual section 501-02 and install the engine undershield.

20. Using IDS, clear diagnostic trouble codes (DTC).

21. * Disconnect IDS and the Midtronics PSC-550 Vehicle Power Supply from the vehicle *.

NOTE:

The road test is only to be performed if the pump or an actuator has been replaced.

^ The route traveled should ensure that the dynamic response system is activated.

22. If the pump or an actuator has been replaced, perform a 10 mile road test on twisty roads to exercise the system.

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23. When the test drive is complete use IDS to verify that no DTCs appear.

24. Refer to GTR Workshop Manual, section 204-06 (60.60.21) to install a new valve block filter.

25. Start the engine and allow to run for a short period.

26. Check and top-up the dynamic response system fluid reservoir to mid-way between the 'MAX' and 'MIN' marks.