讲义参考培训chassis systems

What’sChangedDiscovery31/10/20233:57PM©LandRover2003.Presenter/FilenameSlide4LANDROVER

DISCOVERY3/LR3

IntroductionProgrammeDavidHolme1/10/20233:57PM©LandRover2003.Presenter/FilenameSlide5Preliminaries:Fire,Toilets,FirstAidandRefreshmentsCOURTESYNOIMAGINGCAPTUREEQUIPMENTPERMITTEDCompanyDirective–C114OFFICEAREAKitchenReceptionStoresWorkshopAreaWaterCoolerLGCDStoresWorkAreaTechnicalAcademyLayoutSeatingArea1/10/20233:57PM©LandRover2003.Presenter/FilenameSlide9INTRODUCTIONSWho’sWho?INTRODUCTIONSPrevioustrainingprogrammesYearsofLandRoverexperienceWhichcompanydoyouworkforHowlongatpresentcompanyHobbies/Interests/HumorousIncidentsWhatareyourexpectationsfromthisprogrammeDurationofintroduction–3minutes1/10/20233:57PM©LandRover2003.Presenter/FilenameSlide11WORKINGTOGETHERProgrammeCommitmentWORKINGTOGETHERAcceptashareofresponsibilitytomaketheprogrammeworkRemembertheobjectivesstayfocusedonthetopicalsubjectContributetotheprogrammepositivelyListentowhatothershavetosayConsiderhowtheirideascanbeappliedRelatethecontenttoyourjobfunctionReviewandfeedback1/10/20233:57PM©LandRover2003.Presenter/FilenameSlide13ProgrammeObjectivesSummaryOverviewProgrammeObjectivesAtprogrammeclosedelegateswillbeableto:ExplaintheserviceproceduresorrequirementsDescribesystemmodulelocationsDescribewhattrimsareneededtoberemovedformoduleaccessExplainhighlevelsystemoperationShowT4functionalityanddiagnosticchangeswithabasicexample1/10/20233:57PM©LandRover2003.Presenter/FilenameSlide15SafetyandPrecautionsSafetyFirstWorkshopSafetyGeneralprecautionsWorkshopandPersonnel-SafetyEquipmentGuidelinesChemicalsandSolventsSystemCappingUpdatesDrivingandRegulationsCouldItHappenToYou?HandHeldTelephone!1/10/20233:57PM©LandRover2003.Presenter/FilenameSlide18ChassisOverviewofChangesYouWillBeAbleTo:DescribethechangestothechassissystemExplainwhatserviceablecomponentsexistDescribewhichsuspensioncomponentsareadjustableUseGTRlocategeometrydataListgeometrydatasettingsLocateonGTRservicetoolsassociatedwiththesuspensionsystem1/10/20233:57PM©LandRover2003.Presenter/FilenameSlide20GTRGlobalTechnicalResourceGTR1.General100-GeneralToolsandSpecifications(Jacking,Stands,etc)2.Chassis204–Suspension206–Braking211–Steering3.Powertrain303–Engine307–AutomaticTransmission310–FuelSystemandSpeedControlGTR4.Electrical412–ClimateControl413–InstrumentCluster414–BatteriesandCharging415–EntertainmentSystem417–Lighting418–Modules419–Anti-Theft,Navigation,Telephone,etc5.Body501–BodySystemsGTR-AccessThewebaddressforGTRisasfollows:

1/10/20233:57PM©LandRover2003.Presenter/FilenameSlide24ChassisNotablePointsChassisHydroformedchassismembersDetachable

rearendRemovablesupportfortransferboxreplacementRemovableforfrontdifferentialreplacementVINscribedjustafter

No2bodymountingTwo15KgmassdampersWhyChassis?Whyisachassisusedratherthanamonocoque?Multipleplatformscanbeproducedfromasinglechassis1/10/20233:57PM©LandRover2003.Presenter/FilenameSlide27SuspensionComponentChangesSuspensionSystemsAllnewsuspensionsystemforLandRoverDiscovery3/LR3Canbeeither:AllcoilspringsuspensionFourcornerairsuspensionIndependentdoublewishboneconfigurationfrontandrearFabricatedarmsfordurabilityandrobustnessDoublebondedbushesforoptimumreliabilityHydrabushforfrontsuspensionlowercontrolarmreartoreducewheelvibrationsSuspensionSystemsFrontRear1/10/20233:57PM©LandRover2003.Presenter/FilenameSlide30ChassisFrontSuspensionFrontSuspensionServiceableHydrabushServiceableDoubleBondedBushes(vsNonorSingle)ServiceableBallJointsNonServiceableHubAssemblyAluminiumProtectionGuideSleeveServiceKitsAvailableSuspensionSystemsSuspensionbushesorientationcanbeanyoneofthefollowing:NoalignmentarrowsbushfitsinanypositionTwoalignmentarrowsbushfitseitherwayupOnealignmentarrowmeansbushfitsinonlyonedirectionofalignmentRefertoGTRforlatestinformationorchangesinprocessFront-UpperControlArmRideheightsensorbracket/pinABS/PadwearcablebracketCirclipStabiliserLinkconnectionBushcut-outs/voidstobe90degreesopposedtoarmsplitlineFront-LowerControlArmHydrabushClashinglockstopsBushcut-outs/voidstobe90degreesopposedtoarmsplitlineFrontLowerBallJointCirclipHydrabushOSFReplacedriveshaftnutifdisturbedSplitlineFronthubnotserviceableFrontknuckleNSFOSF1/10/20233:57PM©LandRover2003.Presenter/FilenameSlide37ChassisSteeringSystemsSteeringSystemLayoutSteeringColumnI-ShaftPASPumpReservoirPipesSteeringGearSteeringAngleSensorBulkheadSealsV6PetrolDerivativeFourfixinglocationtoXcarbeamSteeringAngleSensor(3fixinglocation)ColumnlockPlasticadjustmentleverConnectiontoupperI-shaftAdjustmentplatesBreakoutcapsulesSteeringColumnReach40mmRake6°adjustmentEnergyabsorbtionsystem120mmridedowncapabilityPanasonicsteeringanglesensorMainFeatures:SteeringSystemCam-boltfixingtocolumn(Infootwell)Plasticsleeve(throughbulkhead)Fixingforupper/lowershaftconnectioninenginebayFixingtosteeringgearDecouplingmechanismHeatsleeveFlexibleCouplerSteeringIntermediateShaftTwomountingfeetlocationtochassisframeChangefixingsifdisplacedRackpinionconnectiontoI-shaftInternalhexdriveonTRE’sBellowskitavailableforserviceOuterballjointkitandtierodsavailableforserviceSteeringGearSteeringGearOnepieceAluminiumhousingGundrilledrackbarRacktravel:166mm,turnslocktolock:3.32,giving50mm/revratioRackforces:16kN(30mmbardia,52mmpistondia)110barsystempressureSystemratio17.8:1MainFeatures:PASCooler(clippedinplacetoradiator)Reservoir(100filter)BanjoboltHPconnectiontopump(withanti-rotationfeature)PASInstallations–V6PetrolRHDBanjoboltHPconnectiontopump(withanti-rotationfeature)Quick-fitconnector(returntocooler)Rubbermounting-NVHisolatorConstanttensionclipsPASInstallations–V8PetrolLHDBanjoboltHPconnectiontopump(withanti-rotationfeature)Attenuation&twinchamberhosesonallderivativesPASInstallations–V6DieselLHDBanjoboltHPconnectiontopump(withanti-rotationfeature)Attenuation&twinchamberhosesonallderivativesLatchplatefixingtogearSupportbrktsmountedtogearbodyPASInstallations–V8PetrolRHDLPportHPportPressed-onpulleyMountingPASPumpPASFluid:Texaco14135Pumppressure:114±4barFlowrate:9.2±0.5l/minTheoreticaldisplacement:9.6cc/revPumpspeeds: 910rpm/7563rpm(V6Petrol) 865rpm/8645rpm(V8Petrol) 1043rpm/7367rpm(V6Diesel)Max/Minworkingoiltemperature:-40°Cto+120°CPASFluid:Texaco14135MainFeatures:PASPump1/10/20233:57PM©LandRover2003.Presenter/FilenameSlide50ChassisRearSuspensionRearSuspensionServiceKitsAvailableKnucklesServiceableBushesServiceableAdjustableCamberChangeNutIfDisturbedRear-LowerControlArmBushcut-outs/voidstobe90degreesopposedtoarmsplitlineRLCA-FrontBushRear–LowerControlArmBushcut-outs/voidstobe90degreesopposedtoarmsplitlineHandbrakeCableBracketDamperBracketSplitlineRear–UpperControlArmRUCAFrontBushRearKnuckleAssemblyUpperballjointPushinforce>2tonsThreeservicetoolsfor

removeandinstallLowerballjointReplacedonvehicleFiveservicetoolsforremoveandinstallReplacedriveshaftnutifdisturbedRearKnuckleAssemblyRear–ToeLinkOuterCross

AxisJointAntiRotation

AxialJointToeAdjustmentAdjustableRear–ToeLinkToeAdjusterHexagonformforadjustmentAntiRotationfeatureCrossAxisJointSpringandDamperAssembliesSpringoverdamperdesignTwintubedamperelementsameasDefender,RangeRoverFrontspringisacylindrical,singlerate,withopenhelixendsandanupperisolatorseatRearspringisadoublepigtail,withdualratesandupperisolatorseat1/10/20233:57PM©LandRover2003.Presenter/FilenameSlide60SuspensionWorksheet-A1/10/20233:57PM©LandRover2003.Presenter/FilenameSlide61SuspensionReviewQuestionsandAnswersWorksheet‘A’-ReviewWhatsectionforballjointdata?GTRsection:204Whatservicetoolsrequiredforremovingupperballjointassembly?204-503/2and204-719/5Whatservicetoolsrequiredforinstallingupperballjointassembly?204-530/1and204-530/2Whatspecificinstructionswereprovidedforinstallingupperballjoint?AligncutouttoindentationalignmentmarkPositioncirclip90°fromindentationalignmentmarkWorksheet‘A’-ReviewWhatarethegeometrysettingforthefrontsuspension?Castor:4°25’±30’Camber:-30’±45’TotalToe:-10’±10’Howisrearcamberadjusted?RearknuckleupperballjointcamboltsWhatmustbeobservedwheninstallinglowercontrolarmbushes?VoidcutoutsmustbeopposedtotheLCAsplitlineWhatsettingfortoelinkreplacement?13mmbetweengaiterandbracket1/10/20233:57PM©LandRover2003.Presenter/FilenameSlide64ChassisTyrePressureMonitoringInitiatorsWheelSensorsInstrumentPackTPMSECUFasciaSwitchPackTPMSSchematicFuse32(15amp)BatterySupplyFuse36(5amp)IgnitionSupplyPowerSupply125KhzFULLSIZESPAREWHEELLFINITIATORLFINITIATORWHEELSENSORWHEELSENSORECU315Mhz433MhzLFINITIATORLFINITIATORCLUSTERCANBUSRxWHEELSENSORWHEELSENSORTPMSTPMSTPMSSystemOperation:Ondrivingoff,theECUpollseachroadwheelwithLF(125KHz)signalviatheinitiatorinturn(startingLHFgoingclockwise)TheyresponddirectlytotheTPMSECUwithaRFtransmission(315or433MHz)containingauniqueID,pressure,temperatureandaccelerationinformationAseachwheelresponds,itisassignedapositiononthevehicleandmonitoredfortheremainderofthedrivecycleinthatpositionTheinitiatorisnotusedagainunlessthespeedreducestobelow12mph(20km/h)for15minutesTPMSTyrePressures:UptoGVW:Fronts=33PSI-Rears=42PSIPost-PositionIdentification:Sensorstransmitonceaminutewhilstthevehicleisdriving(Spareevery13hours)TherearetwolevelsofdriverwarningAmberindicatorat25%deflation(Front33PSI=25PSI)(Rear42PSI=31PSI)Redindicatorat35%deflation(Front33PSI=21PSI)(Rear42PSI=27PSI)OnHigh-Linevehicles,themessagecentrereplacestheredwarningindicatorandprovidesadditionalinformationaboutthepositionoftheaffectedwheel(s)TPMSFaultDetection:IftheECUorone-or-moresensorfails,theambertell-talewillbelitandawarningdisplayedonthemessagecentre“TyrePressureMonitoringSensorFault”TyrePressureMonitoringSensorFaultTPMSAwarningwillbedisplayedifRFinterferencearoundthevehicleistoostrongforthesystemtowork,butwillbecancelledwheninterferencesubsidesWhenthesensorbatteryislow,itsendsoutaflagtothecontrolmodule,theECU

canbecheckedtodetermineifasensorneedsreplacingTyrePressureMonitoringSensorFaultMessageCentreandLampsWarningLampsAmberwarningindicator=25%Redwarningindicator=35%LowLineSystemHighLineMessageCentreTPMSCustomerEducation:TyrepressureneedtobecheckedandadjustedwhencoldPressurereducesasaircoolsIfcheckingwhilsthotthenpressureshouldbesethighertocompensate(notrecommendedthough)TemperatureChangeExamples:18°C(65°F)–33PSI12°C(55°F)–32PSI7°C(45°F)–31PSI1.6°C(35°F)–30PSI-3.8°C(25°F)–29PSIFasciaSwitchAfasciamountedswitchinformstheTPMSECUofthedifferentvehicle/tyreloadingLEDon=LightTyreLoadingLEDoff=HeavyTyreLoadingPreference=LEDoff(NormalPosition)PressingtheswitchandindicatingtheadditionalloadincreasecancelstheswitchLEDandresetsthesystemtothehigherthresholdNAS–OnethresholdROW–TwothresholdsTPMSTyreChanging:Thebeadbreakermustnotbeusedwithin90degreesofthevalveInordertoreducetheriskofsensordamageduringtyreremovalandrefitting,thesensormustbepositionedcorrectlyinrelationtothefittingarmIfthesensorisremoved,thenut,sealandwashermustbereplacedandthesensorfixingtorquemustbeadheredtoSensorcomponentsareavailableasservicepartsMountingtoolpositiontostarttyrefittingValveinitialpositionRimTyreFittingmachinedirectionofrotationRedarea

:TyrebeadinwheelwellGreenarea

:TyrebeadabovewheelrimTyreRemovalTPMSWheelLearning:ReplacementWheelsIfnewwheelswithsensorsarefittedtoarunningposition,theywillbelearntwhenthevehicleisfirstdrivenandnootheractionisrequiredSpareWheelsIfanewsensorisfittedinthespareposition,theuniqueIDmustbeprogrammeddiagnosticallyorthewheelwillnotbemonitoredItwillbeprovidedonalabelforcompleteassemblies,andisalsoprintedonthecasingofeachsensorIfaknownrunningwheelisexchangedwiththespare,itwillthenbemonitoredasthespare1/10/20233:57PM©LandRover2003.Presenter/FilenameSlide83ChassisAirSuspensionSystemAirSuspensionSchematicRHDAirSuspensionRelayandFusesRelayR7(70amp-Black-N.O)(BJB)Fuse26(20amp-Yellow)(BJB)-BatteryFuse51(5amp-Brown)(CJB)-IgnitionAirSuspensionDesignObjectives:DeliverFastactingsystemoverlargewheeltravels–liftingandloweringConsistentperformanceoverallvehicleenvironments-AltitudeElectronicallycontrolledsystemwithenhancedon-boarddiagnosticsProvidevehiclelevellingindependentofloadMultiplerideheightsOffRoadStandardAccess(Crawl)EnhancedoffroadperformanceNoMotorwayHeightLoweringAirSuspensionUnitsSpringoverdamperdesignconceptTwintubedamperwithdoublebondedlowerbushandweldedspringseatDoublebonded,dualpathtopmountwithseparatesinglebondedreboundbushFrontandrearairspringshavea2.5mmrubbersleevewithanyloncrossfibreplycrimpedtosteelpistonandtopmountTherubbersleevehasanaluminiumcylindercrimpedarounditPolyurethanespringaid/bumpstopNSRAirSuspensionAirSpringandDamperAssemblies:KeyFeaturesGuidedAirSpringoverdamper–duetoworkingpressuresImprovedridecharacteristicovernonguidedAirSpringsBurstpressure35barNormalrunningpressures:Front:8-10barRear:5–8barMaxspringpressure(Fullbump@GVW)circa27bar)DecoupledAirSpringguideAllowsgreaterdamperarticulationwithouttrappingairsleeveAirSuspensionAirSpringandDamperAssemblies:KeyairspringsealingpointsPistontodamperbodyKeyServiceIssues:Component/systemdepressurisationComponent/systemre-pressurisationCarerequiredwhenremoving/refittingairspring/damperassemblytoensuresealsarenotdamagedAirSuspension-ECUUniquecomponentLocatedbehindfaciaonbodysidepanel(‘A’postdriversside)FixedtovehiclebodywithtwoplasticclipsandsingleM8screwRequirescalibrationifreplacedHeightControlLongPress=Locked=CrawlModeDriverInterfaceHeightsindicatedbyuniquesymbolsOffroad55mmaboveStandardAccess50mmdownfromStandardReselectablewhilstvehiclemovingExtendedModeAutomaticallyselectedCrawlindicatedas“LockedatAccess”DirectionofmovementindicatedbyarrowsFlashinglampsnotusedduringnormaloperation–customerfeedbackresponseRemoteoperationviacustomerconfigurablehandset1of3availablesettingsAdditionalinformationviamessagecentreSpeeddataforeachmodeshowninworkbookMessageCentreExampleMessageCentreDisplayFaultIndicatorIndicatorAmber=MinorFaultDetectedIndicatorRed=MajorFaultDetectedAirSupplyUnitAssemblyEvolutionofexistingunitforLandRoverapplicationLocatedonlefthandchassisrail(infrontofrearwheel)Assemblycomprises:AircompressorwithintegralAirdrierIsolationmountsExhaustValve(electricallyswitchedpilotoperated)Doubletemperaturesensors–maximisingdutycycleavailableECUcontrolledMaxpressure:16.8bar(nominal)AcousticboxfornoisecontrolReservoirTwinchamberdesigntoEUpressurevesselguidelinesVolume:9litresWorkingpressure:17.5bar(23max)LocatedoffbodymountbracketsonlefthandchassisrailAirSuspensionValveBlocks:Frontaxleblockassembly–mountedonfrontbumper2xfrontindividualsolenoidoperatedcornervalves1xfrontcrosslinkvalveRearaxleblockassembly–mountedonLHRspringtower2xrearcornervalvesand1xcrosslinkvalveasperfront

VossairfittingsAirSuspensionReservoirvalveblockassembly:PressuresensorinmanifoldtomonitorspringpressuresandreservoirpressureMountedonisolatorstoreducevalvenoiseVossairfittings

AirSuspensionAirHarness:Intake&exhaustpipeslargerIntakeviafilteratrearofvehicle(DiscoveryII–Butondryside)TwinchamberfoamfilledsilencerforintakeandexhaustnoisecontrolInsiderearquarterpanelAirSuspensionAirSuspensionSchematicAirSuspensionHeightSensors:Contactingtechnologyunit4HeightsensorspervehicleSupplyvoltage=5voltsOutputvoltage=0.5vto4.5vBodydown=VoltageupOrArmup=Voltageup6pins–only3usedArmserviceableBlack=RHWhite=LHOnlyoneheightsensorexistsHeightmessagesentoverCANforXenonheadlampsAirSuspensionHeightSensors(continued)SensorsmountedtobracketsonchassisframesiderailsDroplinksareconnectedtosuspensionarmswithoutfixingsHeightsensorreplacementorremovalandrefittingwillresultintheAirSuspensionsystemECUrequiringcalibrationLHROSFNSRHeightAdjustmentToolMultipieceheighttoolArrowindicatesmeasurementpointMorethanonemeasuringpointToolnumber:204-xxx4.5vZero2.5v0.00vBodyDown=ArmUp=Bump=RingC/W-4.5voltsBodyUp=ArmDown=Rebound=RingA/C/W-0.5voltsHeightSensors4.5vZero2.5v0.00vBodyDown=ArmUp=Bump=RingA/C/W-4.5voltsBodyUp=ArmDown=Rebound=RingC/W-0.5voltsHeightSensors

4.5vZero2.5v0.00vBodyDown=ArmUp=BumpBodyUp=ArmDown=ReboundHeightSensorsZero2.5v4.5vZero2.5vZero2.5v0.00vTwinChannelSensor,i.e.TwoRamps(notused)HeightSensorsAirSuspensionSchematicSuspensionSystemsWakeUpModeSystemwakesup2hoursaftertheignitionswitchedoffThenagaineverysixhours(untilaccessheightreachedthenstops)Duringthiswakeupperiodthesystemwillmakesmalladjustments

tolevelthevehicleLevellingonlyoccursinadownwarddirectionTransportationModeRequiresT4toremovefromthismodeSuspensionSystems1/10/20233:57PM©LandRover2003.Presenter/FilenameSlide115WorksheetExercises1/10/20233:57PM©LandRover2003.Presenter/FilenameSlide116Worksheet‘A’-ReviewQuestionsandAnswersWorksheet‘A’-ReviewWhatsectionofGTRwastheballjointdatafoundin?GTRsection204Whatservicetoolsarerequiredforremovingtheuppercontrolarmballjoint?204-503/2and204-719/5Whatservicetoolsarerequiredforinstallingtheuppercontrolarmballjoint?204-530/1and204-530/2Whatspecificinstructionswereprovidedforballjointreplacement?Alignballjointcut-outtoindentationalignmentmarkPositiontheballjointcirclip90°fromalignmentmarkWorksheet‘A’-ReviewWhatarethegeometrysettingsforthefrontsuspensioncamber,casterandtoe?Castor:4°25’±30’Camber:-30’±45’TotalToe:-10’±10’Howistherearcamberadjustmentachieved?RearknuckleupperballjointeccentriccamboltWhatmustbeobservedwheninstallingtherearwardandforwardlowercontrolarmsuspensionbushes?Voidcut-outsmustbeopposedtheLCAsplitlineUsingGTRlocateandrecordtheinformationforthefitmentoftherearsuspensiontoelink,I.e.whatsettingmustbeobserved?13mmsettingdistancebetweenrubbergaiterandbracketRearcambercamboltadjusterBoltinsertedfromfrontMarkpositioninrelationtoarmforreplacementFrontcastorcamboltadjusterBoltinsertedfromfrontMarkpositioninrelationtochassisbracketforreplacementFrontcambercamboltadjusterBoltinsertedfromrearMark