Published: 29-Mar-2018

2007.0 Range Rover Sport (LS), 204-05

Vehicle Dynamic Suspension

Front Air Shock Absorber (G2250067)

REMOVAL AND INSTALLATION

Special Tool(s)

E51385

204-538

Air spring tester

E99789

204-700

Remover - front air shock absorber spindle nut

Part(s)

StepPart nameQualificationQuantity
Step 4Shock absorber seal kitAll vehicles1
Step 9Shock absorber upper mounting nutVehicles with active damping1
Step 11Shock absorber upper mounting nutVehicles without active damping1
Removal
NOTE:

This procedure should also be used to remove the front air spring.


The following step(s) applies to:
All vehicles

  1. Remove the shock absorber and spring assembly.
    Refer to: Front Shock Absorber and Air Spring Assembly (204-05 Vehicle Dynamic Suspension, Removal and Installation).
  2. NOTE:

    If no leak is detected, investigate other areas of the air suspension for faults.

    Check the assembly for leaks. Inflate the module to 4 bar and check for pressure loss. If a leak is suspected, immerse the spring and shock absorber assembly in a tank of water to locate the source of the leak.
  3. E51387
    Drill out the rivet.

The following step(s) applies to:
Vehicles without active damping

  1. E96891
    Using the special tool, remove the nut.
    Special Tool(s): 204-700

The following step(s) applies to:
Vehicles with active damping

  1. E168057
    Release the wiring harness clip.
  2. CAUTIONS:

    • Use a suitable tool positioned between two suds to prevent the shock absorber from rotating during the removal procedure.

    • Install the shock absorber retaining nuts to the 2 studs as shown, to prevent damage to the threads.

    E168058
    Remove the nut.

The following step(s) applies to:
All vehicles

  1. E96900
    Remove the rebound washer.
  2. CAUTIONS:

    • Make sure the protective jaws are installed to the vice. Failure to follow this instruction may result in damage to the component.

    • Do not clamp the shock absorber tube. Failure to follow this instruction may result in damage to the component.

    E96892
    Position the front shock absorber and air spring assembly in a vice.
  3. E96893
    Remove and discard the 3 spacers and 2 'O' ring seals.
  4. E96894
    Remove the air spring. Using a soft faced mallet, gently tap the sleeve support upwards to release it from the O-ring seals.
  5. NOTE:

    Note the fitted position.

    E96895
    Remove the bump plate and spring aid.
  6. E96896
    Remove and discard the 2 large black O-ring seals from the lower seal carrier.
  7. Remove the shock absorber from the vice.
Installation

The following step(s) applies to:
All vehicles

  1. CAUTIONS:

    • Make sure the protective jaws are installed to the vice. Failure to follow this instruction may result in damage to the component.

    • Do not clamp the shock absorber tube. Failure to follow this instruction may result in damage to the component.

    E96892
    Position the shock absorber in a vice.
  2. CAUTION:

    Use compressed air and lint free non-flocking material.

    Clean the components.
  3. E96897
    Lift the seal carrier to expose the 'O' ring seal stack. Make sure that the damper body 'O' ring seals and spacers are fully seated to the spring seat.
  4. CAUTION:

    Take care not to damage the O-ring seals during installation.

    E96898
    Apply loctite 8021 to the 'O' ring seals. Install new 'O' ring seals to the seal carrier.
    Renew Part: Shock absorber seal kit Quantity: 1.
  5. NOTE:

    Make sure that these components are installed to the noted removal position.

    E96899
    Install the bump plate and spring aid.
  6. E99908
    Install the air spring. Align the sleeve support with the first 'O' ring seal making sure that the location tag is correctly aligned with the spring seat cut-out.
  7. CAUTION:

    Take care not to damage the O-ring seals during installation.

    NOTE:

    Make sure that the threads of the front air shock absorber are covered with protective tape.

    E96893
    Install the components in the following order: 1. 'O' ring seal 2. Spacer 3. 'O' ring seal 4. Spacer 5. Spacer
  8. NOTE:

    The "T5" stamp on the upper face of the rebound washer must be visable after assembly.

    E96900
    Install the rebound washer.

The following step(s) applies to:
Vehicles with active damping

  1. CAUTIONS:

    • Use a suitable tool positioned between two studs to prevent the shock absorber from rotating during the tightening procedure.

    • Install the shock absorber retaining nuts to the 2 studs as shown, to prevent damage to the threads.

    E168058
    Install and tighten a new nut
    Renew Part: Shock absorber upper mounting nut Quantity: 1.
    Torque: 98Nm
  2. E168057
    Install the wiring harness clip.

The following step(s) applies to:
Vehicles without active damping

  1. E96891
    Install and tighten a new nut and using the special tool.
    Special Tool(s): 204-700
    Renew Part: Shock absorber upper mounting nut Quantity: 1.
    Torque: 98Nm

The following step(s) applies to:
All vehicles

  1. CAUTIONS:

    • The air supply must be free of any moisture.

    • If during disassembly the air sleeve is unrolled, the air sleeve may inflate incorrectly (to one side). If this occurs, release the air pressure, and insert a suitable tool that will not damage the air sleeve or piston (a screw driver handle), into the side opposite the bulge. Inflate and deflate until the air sleeve inflates correctly (the air sleeve will be uniform inside the shroud).

    NOTE:

    To prevent damage when seating the sleeve support over the large black O-rings, compressed air should be used to inflate the air spring.

    E51445
    Using the special tool coupled to a tire inflator with a gauge, apply approximately 2 bar of air pressure to the air spring to fully seat the sleeve support over the O-ring seals
    Special Tool(s): 204-538
  2. Check the assembly for leaks. Inflate the module to 4 bar and check for pressure loss. If a leak is suspected, immerse the spring and shock absorber assembly in a tank of water to locate the source of the leak.
  3. Depressurize and remove the special tool from the shock absorber and air spring assembly.
  4. E51387
    Install a new rivet.
    5. NOTE:

    Install a new air spring pipe connector.

  5. Install the shock absorber and spring assembly.
    Refer to: Front Shock Absorber and Air Spring Assembly (204-05 Vehicle Dynamic Suspension, Removal and Installation).