Range Rover P38 EAS air suspension valve block diaphragm seal replacement fix

Range Rover P38 EAS air suspension valve block diaphragm seal replacement fix

Leak from EAS system but no visable leaks when testing components, vehicle on bump stops? Slow leak? Complete failure of EAS system?

Models Affected:

 

£12.99
 
Description

Additional Information

Ebay Text
Ebay Text 2 No
Model Affected No
The Problem

 

The Problem

 

 

Leak from EAS system but no visable leaks when testing components, vehicle on bump stops? Slow leak? Complete failure of EAS system?

 
               RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731

The diaphragm seal within your vehicles EAS valve block system can wear causing the symptoms noted above.

 

The diaphragm wearing can lead to the compressor overworking and can cause complete EAS falure, we always recommend replacing the diaphragm seal when replacing the o-rings in the valve block as both can cause leaks and EAS failure.

 
     
The Solution

The Solution

Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement

Fit our OEM design diaphragm seal and restore your
EAS system to full health.

Our diaphragm seal is made in the same way as the OEM seal, beware of aftermarket designs that cause the compressor to run on and burn out, this part is precision made to prevent this.

Accompanied with a Viton O-ring far better than Silicone O-rings offered by others.

 

 

                  

Complete Kit

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
   
Vehicle Compatibility

 Vehicles Affected

   
 RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731

 


Range Rover Classic 1993-1996

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731



Range Rover P38 1994–2002

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731



Many Citroen and LDV models

  Associated part numbers: 
  E311660030 , 38769609 
   
   


FAQ

Instructions

 

 

 

Range Rover P38 EAS Air Suspension Compressor Piston Seal and Filter Replacement Instructions

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
 

Step 1: Replace filters

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731

Unscrew filter unit from compessor.

Lift lid off of filters, remove old filters, clean filter unit and fit new filters.

Reattach filter unit to compressor.

 

 Step 2: Remove compressor head

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731

Remove 4 bolts on cylinder head, it is good practice to label each bolt so that they can be refitted in their original position. Use a socket rather than a Torx screwdriver to remove as the bolts are relatively soft.

Remove cylinder head cover.

Remove head, locate O-ring and remove, we shall replace that later.

Remove piston liner.

 

 Step 3: Remove face plate

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731

Again using a socket and remembering location for respective bolts remove 3x bolts on face plate.

Remove gasket and remember orientation for reinstallation.

 

Step 4: Remove piston

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
 

Remove grub screw shown on side of compressor.

Rotate piston through face plate opening and look down the hole left from the removal of the grub screw until you can see a bolt head through the hole.

Loosen this bolt so as the piston is loose enough to move off of its shaft.

This will release the piston, slide off of shaft and remove through face plate opening, take care not to bend the piston if you need to lever out of position.

 

 Step 5: Replace piston seal

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
 
Take a sharp knife and cut away as much of the old seal as you can.
 
Cut away as much of the seal as you can between the clamp ring and the piston.
 
Using a screw driver incrementing in size, lever away at gap between clamp ring and piston.
 
Raise the clamp ring slowly and in increments making sure not to damage the piston or clamp ring.
 
Once clamp ring is removed clean clamp ring and piston removing old seal and any remnants.
 
Fit new piston seal from our kit.
 
Apply Loctite to clamp ring and refit over seal.
 
Use a socket a similar size in circumference to the clamp ring and tap this down so that it retains the new seal, the clamp ring should sit the same as it did with the old seal.
 
Fit piston liner to shape seal (if using one of our replacement piston liners fit this and dispose of old liner)
 
Fit liner at 45 degree angle and slowly rotate to fully engage seal, do so slowly and in increments to shape the seal.
 
 

Step 6: Refit piston

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731

Refit piston to shaft.

Tighten grub screw to tighten piston on shaft.

Screw back in place larger grub screw on side of compressor.

Refit piston liner.

 

 Step 7: Replace o-rings in head

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731

Remove two shims as shown.

Take note of orientation of shims.

Clean up shims removing residue of old O-ring.

Pry out old O-ring and clean recess.

Fit our new O-ring with a small amount of silicone sealant.

Apply Loctite to the screw and reattach shims.Make sure shims are parallel and together.

Replace larger O-ring with our new O-ring, location shown.

 

Step 8: Re-fit head and face plate and test

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731

Apply Loctite to bolts and refit head.

Apply Loctite to bolts and refit face plate -remembering gasket.

Refit filter unit.

Test unit on bench to confirm successful repair.

Connect lead from 12v battery positive terminal to Green wire from compressor, connect negative terminal lead to Black wire from compressor, this will run the compressor.

Check for good output and proceed to refit to vehicle.

 
 
 
 

Video Tutorial

 

 

Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement Instructions Guide

  Picture of Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement Instructions Guide
   
 

Step 1: Removing EAS unit

 

De-pressurise the EAS system using a tool of your choice, much software is available for this, please contact us should you need any recommendations.

After De-pressurising the system ensure ignition is switched off until repair is complete.

Remove valve stems to stop any build up of pressure anywhere in the system.

Remove valve block from vehicle labelling air lines and bolts to speed up reinstallation.

   
 

Step 2: Remove solenoid covers

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
 

Label solenoid covers 1-7 and remember orientation for reinstallation.

Remove 7x solenoid covers (5 on top side 2 on underside).

   
 

Step 3: Remove solenoid bases

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
 

Label solenoid bases 1-7 and remember orientation for reinstallation.

Remove 7x solenoid bases (5 on top side 2 on underside).

   
 

Step 4: Remove diaphragm block

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
 

Remove 4x Allen bolts and remove diaphragm block.

Remove old diaphragm seal retain both parts, remove O-ring seal around diaphragm seal.

Retain diaphragm spring.

   
 

Step 5: Remove Non Return Valves Block

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
 

Remove 4x Allen bolts shown and lift off block.

Take note of location and orientation of NRV's.

Remove NRV's and O-rings.

   
 

 Step 6: Remove collets and O-rings

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
 

Prise out collets with screw driver.

Remove the 2x O-rings in each hole the collets were removed from, for this use a plastic screwdriver or a tool softer than the valve block.

Before fitting new O-rings give each of the holes a clean removing any dirt.

   
 

Step 7: Replace O-rings Non Return Valve Block

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
   

When replacing these O-rings and all other O-rings we recommend using lubrication on the O-rings to assist in sealing, di-electric grease or Vaseline are well suited.

Replace O-rings on the NRV block.

Replace O-rings on the NRV's, do not lubricate NRV's.

Refit NRV block and tighten bolts.

   
 

 Step 8: Replace Diaphragm O-ring and Diaphragm Seal

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
 

Replace O-ring around diaphragm seal.

Take old diaphragm seal, remove center part of seal (this part doesn't wear) separate this from outer rubber seal.

Insert this in to the center of our replacement seal, you will then see this looks almost identical to how the OEM seal looked (taking in to account wear).

Fit new seal and refit spring (important).

Refit block and tighten bolts.

   
 

Step 9: Fit O-rings air line holes

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
 

Fit O-rings in to airline holes, each hole takes 2x O-rings, it will be evident which holes take which sized O-rings.

Tap down O-rings with the blunt end of a drill bit or using a similar tool.

Push collets back in to holes.

   
 

Step 10: Replace solenoid O-rings

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
 

Replace O-rings on solenoids one at a time.

Unscrew cover, remove valve stem and replace O-ring ensuring the O-ring doesn't bind and that it sits flush to the stem. Reassemble and replace 2x O-rings on base of solenoid and 1x O-ring on top of solenoid (small solenoid doesn't have top O-ring).

Repeat process for all 7 solenoids, repairing just one at a time.

   
 

Step 11: Refit solenoids and covers

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
 

Refit solenoids and covers in same place and orientation as removed, remove any labels attached at start to remember orientation.



Installation is carried out at installers risk, if unsure please contact us or a professional, X8R Ltd cannot be held responsible for any adverse result of installing this product or any injuries caused by install, if in doubt ask a professional. All images and texts are copyright X8R Ltd 2013.

   
   
   
 

Video Tutorial

 

 

 

 

 

REVIEWS
For Car No

 

The Problem

 

 

Leak from EAS system but no visable leaks when testing components, vehicle on bump stops? Slow leak? Complete failure of EAS system?

 
               RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731

The diaphragm seal within your vehicles EAS valve block system can wear causing the symptoms noted above.

 

The diaphragm wearing can lead to the compressor overworking and can cause complete EAS falure, we always recommend replacing the diaphragm seal when replacing the o-rings in the valve block as both can cause leaks and EAS failure.

 
     

The Solution

Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement

Fit our OEM design diaphragm seal and restore your
EAS system to full health.

Our diaphragm seal is made in the same way as the OEM seal, beware of aftermarket designs that cause the compressor to run on and burn out, this part is precision made to prevent this.

Accompanied with a Viton O-ring far better than Silicone O-rings offered by others.

 

 

                  

Complete Kit

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
   

 Vehicles Affected

   
 RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731

 


Range Rover Classic 1993-1996

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731



Range Rover P38 1994–2002

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731



Many Citroen and LDV models

  Associated part numbers: 
  E311660030 , 38769609 
   
   


Instructions

 

 

 

Range Rover P38 EAS Air Suspension Compressor Piston Seal and Filter Replacement Instructions

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
 

Step 1: Replace filters

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731

Unscrew filter unit from compessor.

Lift lid off of filters, remove old filters, clean filter unit and fit new filters.

Reattach filter unit to compressor.

 

 Step 2: Remove compressor head

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731

Remove 4 bolts on cylinder head, it is good practice to label each bolt so that they can be refitted in their original position. Use a socket rather than a Torx screwdriver to remove as the bolts are relatively soft.

Remove cylinder head cover.

Remove head, locate O-ring and remove, we shall replace that later.

Remove piston liner.

 

 Step 3: Remove face plate

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731

Again using a socket and remembering location for respective bolts remove 3x bolts on face plate.

Remove gasket and remember orientation for reinstallation.

 

Step 4: Remove piston

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
 

Remove grub screw shown on side of compressor.

Rotate piston through face plate opening and look down the hole left from the removal of the grub screw until you can see a bolt head through the hole.

Loosen this bolt so as the piston is loose enough to move off of its shaft.

This will release the piston, slide off of shaft and remove through face plate opening, take care not to bend the piston if you need to lever out of position.

 

 Step 5: Replace piston seal

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
 
Take a sharp knife and cut away as much of the old seal as you can.
 
Cut away as much of the seal as you can between the clamp ring and the piston.
 
Using a screw driver incrementing in size, lever away at gap between clamp ring and piston.
 
Raise the clamp ring slowly and in increments making sure not to damage the piston or clamp ring.
 
Once clamp ring is removed clean clamp ring and piston removing old seal and any remnants.
 
Fit new piston seal from our kit.
 
Apply Loctite to clamp ring and refit over seal.
 
Use a socket a similar size in circumference to the clamp ring and tap this down so that it retains the new seal, the clamp ring should sit the same as it did with the old seal.
 
Fit piston liner to shape seal (if using one of our replacement piston liners fit this and dispose of old liner)
 
Fit liner at 45 degree angle and slowly rotate to fully engage seal, do so slowly and in increments to shape the seal.
 
 

Step 6: Refit piston

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731

Refit piston to shaft.

Tighten grub screw to tighten piston on shaft.

Screw back in place larger grub screw on side of compressor.

Refit piston liner.

 

 Step 7: Replace o-rings in head

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731

Remove two shims as shown.

Take note of orientation of shims.

Clean up shims removing residue of old O-ring.

Pry out old O-ring and clean recess.

Fit our new O-ring with a small amount of silicone sealant.

Apply Loctite to the screw and reattach shims.Make sure shims are parallel and together.

Replace larger O-ring with our new O-ring, location shown.

 

Step 8: Re-fit head and face plate and test

RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731
RANGE ROVER P38 EAS AIR SUSPENSION COMPRESSOR PUMP SEAL REPAIR FIX KIT ANR3731

Apply Loctite to bolts and refit head.

Apply Loctite to bolts and refit face plate -remembering gasket.

Refit filter unit.

Test unit on bench to confirm successful repair.

Connect lead from 12v battery positive terminal to Green wire from compressor, connect negative terminal lead to Black wire from compressor, this will run the compressor.

Check for good output and proceed to refit to vehicle.

 
 
 
 

Video Tutorial

 

 

Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement Instructions Guide

  Picture of Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement Instructions Guide
   
 

Step 1: Removing EAS unit

 

De-pressurise the EAS system using a tool of your choice, much software is available for this, please contact us should you need any recommendations.

After De-pressurising the system ensure ignition is switched off until repair is complete.

Remove valve stems to stop any build up of pressure anywhere in the system.

Remove valve block from vehicle labelling air lines and bolts to speed up reinstallation.

   
 

Step 2: Remove solenoid covers

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
 

Label solenoid covers 1-7 and remember orientation for reinstallation.

Remove 7x solenoid covers (5 on top side 2 on underside).

   
 

Step 3: Remove solenoid bases

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
 

Label solenoid bases 1-7 and remember orientation for reinstallation.

Remove 7x solenoid bases (5 on top side 2 on underside).

   
 

Step 4: Remove diaphragm block

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
 

Remove 4x Allen bolts and remove diaphragm block.

Remove old diaphragm seal retain both parts, remove O-ring seal around diaphragm seal.

Retain diaphragm spring.

   
 

Step 5: Remove Non Return Valves Block

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
 

Remove 4x Allen bolts shown and lift off block.

Take note of location and orientation of NRV's.

Remove NRV's and O-rings.

   
 

 Step 6: Remove collets and O-rings

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
 

Prise out collets with screw driver.

Remove the 2x O-rings in each hole the collets were removed from, for this use a plastic screwdriver or a tool softer than the valve block.

Before fitting new O-rings give each of the holes a clean removing any dirt.

   
 

Step 7: Replace O-rings Non Return Valve Block

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
   

When replacing these O-rings and all other O-rings we recommend using lubrication on the O-rings to assist in sealing, di-electric grease or Vaseline are well suited.

Replace O-rings on the NRV block.

Replace O-rings on the NRV's, do not lubricate NRV's.

Refit NRV block and tighten bolts.

   
 

 Step 8: Replace Diaphragm O-ring and Diaphragm Seal

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
 

Replace O-ring around diaphragm seal.

Take old diaphragm seal, remove center part of seal (this part doesn't wear) separate this from outer rubber seal.

Insert this in to the center of our replacement seal, you will then see this looks almost identical to how the OEM seal looked (taking in to account wear).

Fit new seal and refit spring (important).

Refit block and tighten bolts.

   
 

Step 9: Fit O-rings air line holes

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
 

Fit O-rings in to airline holes, each hole takes 2x O-rings, it will be evident which holes take which sized O-rings.

Tap down O-rings with the blunt end of a drill bit or using a similar tool.

Push collets back in to holes.

   
 

Step 10: Replace solenoid O-rings

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
 

Replace O-rings on solenoids one at a time.

Unscrew cover, remove valve stem and replace O-ring ensuring the O-ring doesn't bind and that it sits flush to the stem. Reassemble and replace 2x O-rings on base of solenoid and 1x O-ring on top of solenoid (small solenoid doesn't have top O-ring).

Repeat process for all 7 solenoids, repairing just one at a time.

   
 

Step 11: Refit solenoids and covers

  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
  Range Rover P38 EAS Air Suspension Valve Block O-rings and Diaphragm Seal Replacement
 

Refit solenoids and covers in same place and orientation as removed, remove any labels attached at start to remember orientation.



Installation is carried out at installers risk, if unsure please contact us or a professional, X8R Ltd cannot be held responsible for any adverse result of installing this product or any injuries caused by install, if in doubt ask a professional. All images and texts are copyright X8R Ltd 2013.

   
   
   
 

Video Tutorial