Suspension Warning Lamp Illuminated – Diagnostic & Repair Procedure – 2006-2013 Land Rover Range Rover Sport

TECHNICAL BULLETIN
LTB00057NAS5
05 AUG 2014


 

SECTION: 204-06

Suspension Warning Lamp Illuminated – Diagnostic & Repair Procedure

 

AFFECTED VEHICLE RANGE:

Range Rover Sport (LS)
Model Year:
 2006-2013
VIN: 6A901924-DA814822

 

MARKETS:

NAS

 

CONDITION SUMMARY:

Situation: The Dynamic Response system red warning lamp may be illuminated on the Instrument Cluster and Diagnostic Trouble Codes (DTC) C1119-62, C1119-09, and/or C1B11-62 may be stored, possibly indicating system contamination.

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 to clean the affected parts that do not need to be replaced and ensure that the issue does not re-occur.

Action: Should a customer express concern, use SDD to establish which actuator is at fault and carry out the flush and repair procedure by following the Service Instruction outlined below.

 

PARTS:

LR014592 High pressure pipe repair kit – from 2010MY Quantity: 1
LR014593 High pressure pipe front – from 2010MY Quantity: 1
LR014595 Pump – from 2010MY Quantity: 1
LR024072 Rear actuator – from 2010MY Quantity: 1
LR024073 Rear actuator – up to 2010MY Quantity: 1
LR032958 Front actuator – up to 2007MY Quantity: 1
LR032959 Front actuator – from 2007MY Quantity: 1
RQB500393 High pressure pipe front – up to 2010MY Quantity: 1
RQN000011 Reservoir Quantity: 1
RVB000017 Pump – up to 2010MY Quantity: 1
RVH500100 Pressure Control Valve (PCV) Quantity: 1
RVH500110 Valve block Quantity: 1
RVJ100010 Valve block filter Quantity: 1

 

TOOLS:

Dynamic Response system Bleed Bottle 204-591-01 Dynamic Response system Bleed Bottle 204-591-01
Dynamic Response system Control Box 204-591-02 Dynamic Response system Control Box 204-591-02
Hose Plier clamp-off tools
SDD with latest DVD and Calibration File Jaguar Land Rover-approved Midtronics battery power supply

 

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 TOPIx to obtain the latest repair time.

NOTE: DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.

DESCRIPTION SRO TIME (HOURS) CONDITION CODE CAUSAL PART
Dynamic Response system – Check using SDD – Replace pump – 4.2L / 5.0L V8 SC 60.60.89/41 1.9 49 RQK500110
Dynamic Response system – Check using SDD – Replace pump – 4.4L / 5.0L V8 N/A 60.60.89/41 1.8 49 RQK500110
Dynamic Response system – Pressure test using SDD – Replace valve block 60.60.89/42 2.4 49 RQK500110
Dynamic Response system – Check using SDD – Replace front actuator; flush and bleed system 60.60.89/43 4.2 49 RQK500110
Dynamic Response system – Check using SDD – Replace rear actuator; flush and bleed system 60.60.89/44 5.9 49 RQK500110
Dynamic Response system – Check using SDD – Replace front actuator; replace high-pressure pipe front section; flush system – 4.2L / 5.0L V8 SC 60.60.89/47 4.3 49 RQK500110
Dynamic Response system – Check using SDD – Replace front actuator; replace high-pressure pipe front section; flush system – 4.4L / 5.0L V8 N/A 60.60.89/47 4.2 49 RQK500110
Pressure Control Valve – Renew 60.60.23 0.4 49 RQK500110
Dynamic Response system – Pressure test 60.90.20 0.4 49 RQK500110

NOTE: Normal Warranty procedures apply.

 

SERVICE INSTRUCTION:

1. Connect the Jaguar Land Rover-approved Midtronics battery power supply to the vehicle battery.

2. Turn ignition ‘ON’ (engine not running).

3. Connect the Symptom Driven Diagnostics (SDD) system to the vehicle and begin a new session.

4. Follow the on-screen prompts, allowing SDD to read the VIN and identify the vehicle and initiating the data collect sequence.

5. Read and record all Diagnostic Trouble Codes (DTC).

  • Follow the Service Instruction if any of the following DTC codes are present: C1119 62, C1119 09, C1B 1162.

6. CAUTION: If the Dynamic Response system reservoir is empty, pump damage is likely to have occurred.

Check the Dynamic Response system fluid level.

  • If the level is correct, proceed to step 12.
  • If the fluid is low, inspect system for leaks.

7. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle (see TOPIx Workshop Manual, section: 100-02).

8. Remove the engine under shield (see TOPIx Workshop Manual, section: 501-02).

9. Remove the radiator access panel.

radiator access panel

 

10. Remove the right-hand splash shield.

right-hand splash shield

 

11. Inspect the Dynamic Response system for leaks.

12. Using SDD, perform the Dynamic Response system test.

  • Select ‘Special Applications’.
  • Select ‘Dynamic Response system Hydraulic Control – System Test’.
  • Demand 50 Bar of pressure for up to five minutes or until the primary circuit pipes (A) are hot. Check pipe temperature under right-hand wheel arch.
  • If 50 bar cannot be obtained then the Pressure Control Valve (PCV) in the valve block is faulty and requires replacement with the PCV service kit (see TOPIx Workshop Manual, Section: 204-06).
  • Open Directional Control Valve 1 (DCV1) and check system pressure is still 50 Bar. Hold for two minutes. If pressure has dropped by over 5 Bar, this indicates a faulty actuator.
  • Open Directional Control Valve 2 (DCV2) and check system pressure is still 50 Bar. Hold for two minutes. If pressure has dropped by over 5 Bar, this indicates a faulty actuator.

four pipes in the front wheel arch area

 

13. NOTE: If the temperature comparison test is not conclusive at this stage, follow the bulletin and if condition (B) is found at step 22, the front actuator requires replacement.

Confirm which actuator is faulty.

  • If all four pipes in the front wheel arch area are hot and at a similar temperature, this indicates that the front actuator is faulty. Replace the front actuator (see TOPIx Workshop Manual, section 204-06).
  • If the pipes in the rear wheel arch are hot, this indicates that the rear actuator is at fault. Replace the rear actuator (see TOPIx Workshop Manual, section 204-06).
  • If the pressure has dropped but there is no increase in the actuator pipes temperature (B), and rear pipes, then the valve block requires replacement (see TOPIx Workshop Manual, section 204-06). There should be a corresponding DCV fault code logged.

14. If found faulty in step 12, install a new Pressure Control Valve (PCV) service kit (see TOPIx Workshop Manual, Section: 204-06). Once complete, check the valve block and reservoir filter for signs of debris (steps 15-22). Complete bleed process. If no debris found in reservoir of valve block filter. It will not be necessary to follow the other steps shown in this procedure.

15. Remove the valve block filter (see TOPIx Workshop Manual, Section: 204-06).

16. Inspect the valve block filter.

  • Check filter for signs of distortion. A distorted filter indicates excessive system pressure.
  • Replace the filter.

valve block filter

 

17. Release the Dynamic Response system reservoir.

  • Release the clip.
  • Tie the reservoir aside.

Dynamic Response system reservoir

 

18. Disconnect the intake air resonator.

  • Release the clip.

19. Remove the right-hand air cleaner assembly.

  • Disconnect the right-hand Mass Air Flow (MAF) sensor electrical connectors.

Mass Air Flow (MAF) sensor

 

20. Position container to collect fluid loss.

21. CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections is clean. Plug open connections to prevent contamination.

NOTE: Some fluid spillage is inevitable during this operation.

Remove the fluid reservoir.

  • Disconnect the hoses from the fluid reservoir.
  • Using a suitable tool clamp the hoses to prevent air ingress.
  • Release the two clips.

22. NOTE: A small number of particles is acceptable (A). The reservoir does not require replacement.

Inspect the reservoir fluid filter for signs of contamination.

  • A small number of particles is acceptable (A). The reservoir does not require replacement.
    • If the filter is lightly contaminated with grey metallic looking particles, this would indicate a pump failure. Discard the reservoir if this condition is found. Proceed to next step.
    • If the filter is heavily contaminated with black particles and sludge (B), this would indicate an actuator internal piston seal failure. Discard the reservoir. Proceed to step 24.

reservoir fluid filter

 

23. If required, install a new Dynamic Response system pump. It will not be necessary to change any actuator if the pump is replaced.

24. NOTE: ‘A’: all AJV8 petrol engines; ‘B’: TDV8 diesel only.

Inspect the high-pressure hose crimps for signs of movement.

  • A = all AJV8 petrol engines
  • B = TDV8 diesel only

high-pressure hose crimps

 

25. Any pipe assembly that shows signs of movement must be replaced.

  • Any gap larger than 1mm is not acceptable.

signs of movement

 

26. Replace the hose assembly as follows.

  • AJV8 petrol models the hose assembly shown in graphic E93391 [see step 24 (A)] must be replaced if required.

27. Install the fluid reservoir.

  • Clean the component mating faces.
  • Connect the hoses.
  • Install the clips.

28. Remove the hose clamps.

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

Install the right-hand air cleaner assembly.

  • Connect the right-hand Mass Air Flow (MAF) sensor electrical connectors.

Mass Air Flow (MAF) sensor

 

30. NOTE: It is not necessary to perform this step if the valve block or pump has been replaced.

Remove the contaminated fluid from the actuator, without the internal leak.

  • Disconnect both the stabilizer bar links from the stabilizer bar (see TOPIx Workshop Manual, section 204-06).
  • Disconnect the Dynamic Response system fluid pipes from the actuator.
  • Move the actuator bar arms in opposite directions to displace the fluid. Full movement in both directions of each arm must be performed, to ensure fluid from both sides of the piston is removed.

31. Install the special tool to the Dynamic Response system reservoir.

  • Completely fill the reservoir with fluid.
  • Make sure the pressure regulator on the special tool is turned OFF.
  • Fill the special tool bottle approximately ¾ full with fluid.
  • Connect the special tool to a suitable workshop air supply.

special tool

 

32. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle (see TOPIx Workshop Manual, section: 100-02).

33. Disconnect the two valve block actuator control valve electrical connectors.

valve block actuator control valve

 

34. Connect the special tool electrical connectors to the valve block.

  • Connect the special tool power supply leads to the vehicle battery.

special tool

 

35. Disconnect the Dynamic Response system fluid pipes from the actuator.

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

special tool

 

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

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

Connect the fluid lines to the actuator.

  • Tighten the two bolts to 22Nm (16lbf. ft).

39. Repeat the flush process for the rear pipes.

  • If the pipes have not been disconnected during step 30, disconnect the Dynamic Response system fluid pipes from the actuator.
  • Flush fluid through the actuator until approximately 0.5 liter has been displaced.

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

Install a new actuator and stabilizer bar (see TOPIx Workshop Manual, section: 204-06).

41. Bleed the Dynamic Response system (see TOPIx Workshop Manual section: 204-06).

42. Check and top up the Dynamic Response system fluid reservoir.

  • Fill the reservoir to the mid-way mark between the ‘MAX’ and ‘MIN’ marks.

43. Install the radiator access panel.

  • Tighten the bolts to 10Nm.

radiator access panel

 

44. Install the right-hand splash shield.

right-hand splash shield

 

45. Install the engine under shield (see TOPIx Workshop Manual, section: 501-02).

46. Clear diagnostic trouble codes (DTCs).

47. CAUTION: Only perform the road test if the pump or an actuator has been replaced.

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

48. Install a new valve block filter (see TOPIx Workshop Manual, section: 204-06).

49. Check and top up the Dynamic Response system fluid reservoir.

  • Fill the reservoir to the mid-way mark between the ‘MAX’ and ‘MIN’ marks.

 

 

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