Land Rover Defender: Shock Absorber and Spring Assembly - [+] Air Suspension

REMOVAL AND INSTALLATION

SPECIAL TOOL(S)

JLR-204-802

Splitter, Damper

GENERAL EQUIPMENT

PART(S)

REMOVAL

WARNING: Residual air pressure may be present in the system. Take care when releasing air line connectors.

CAUTION: Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all openings must be sealed.

NOTE:

• This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
• This procedure contains illustrations showing certain components removed to provide extra clarity.
• This procedure contains illustrations for left side components, right side components are similar.

1.

CAUTION: This step must be completed in order to maintain the correct compressor/dryer performance.

Use the Jaguar Land Rover (JLR) approved diagnostic equipment to depressurize the front air spring.

2. Disconnect the startup battery ground cable.

3. Raise and support the vehicle on a suitable 2-post lift.

4. Remove the front wheel and tire assembly.

5.

• Disconnect the air line from the front shock absorber and air spring assembly.
• Disconnect the electrical connector from the front shock absorber and air spring assembly.

6.

• Release the wiring harness from the bracket at 2 clips.
• Remove and discard the nut.
• Release the bracket from the yoke.
• Disconnect the front stabilizer bar link from the yoke.

7.

Use a suitable transmission jack to support the front suspension.

General Equipment: Transmission jack

8.

Remove and discard the yoke to front shock absorber and air spring assembly nut and bolt.

9.

Use the special tool release the yoke from the front shock absorber and air spring assembly.

Special Tool(s): JLR-204-802

10.

Remove and discard the yoke to lower arm nut and bolt.

11.

Lower the transmission jack.

12.

NOTE: Note the orientation of the component prior to removal.

Remove the yoke from the front shock absorber and air spring assembly.

13.

WARNING: This step requires the aid of another technician.

NOTE: Note the orientation of the component prior to removal.

• Remove the 4 nuts.
• Remove the front shock absorber and air spring assembly.

14.

NOTES:

• Do not disassemble further if the component is removed for access only.
• Note the orientation of the component prior to removal.

• Remove the 2 clamps.
• Remove the ruber boot from the front shock absorber and air spring assembly.

INSTALLATION

1.

• Install the ruber boot to the front shock absorber and air spring assembly.
• Install the 2 clamps.

  Renew Part: Shock absorber boot kit Quantity: 1.

2.

WARNING: This step requires the aid of another technician.

NOTE: Install the component as previously noted at the removal.

• Install the front shock absorber and air spring assembly.
• Install and tighten the 4 nuts.

  Renew Part: Shock absorber nut Quantity: 4.

  Torque: 40Nm

3.

CAUTION: Make sure the component installed in the correct position.

Install the yoke to the front shock absorber and air spring assembly.

4.

CAUTION: Nuts and bolts must be tightened with vehicle at normal ride height.

• Raise the transmission jack.
• Install and tighten the yoke to front shock absorber and air spring assembly nut and bolt.

  Renew Part: Shock absorber to yoke nut(s) and bolt(s) Quantity: 1.

  Torque: 95Nm

• Install and tighten the yoke to lower arm nut and bolt.

  Renew Part: Yoke to lower arm nut(s) and bolt(s) Quantity: 1.

  Torque

  • Stage1: 100Nm
  • Stage2: 240º
• Remove the transmission jack.

5.

• Connect the front stabilizer bar link to the yoke.
• Secure the bracket to the yoke.
• Install and tighten the front stabilizer bar link nut.

  Renew Part: Stabilizer bar link upper nut Quantity: 1.

  Torque: 185Nm

• Secure the wiring harness to the bracket at 2 clips.

6.

CAUTION: Do not reuse the air line connectors. Always install a new air line connector every time it is released.

Connect the air line to the front shock absorber and air spring assembly.

Renew Part: Air line connector(s) Quantity: 1.

Torque: 3.5Nm

7. Connect the electrical connector to the front shock absorber and air spring assembly.

8. Install the front wheel and tire assembly.

9. Connect the startup battery ground cable.

10.

CAUTION: This step must be completed before the vehicle is fully lowered. Failure to follow this instruction might result in damage to the component.

Use the Jaguar Land Rover (JLR) approved diagnostic equipment to complete the air suspension manual control procedure.

11.

CAUTION: This step must be completed in order to maintain the correct compressor/dryer performance.

Use the JLR approved diagnostic equipment to pressurize the front air spring.

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