Air Suspension Valve Block Rebuild (4.0/4.6)
O-rings
Description

The valve block can be fairly easily disassembled into its component parts and rebuilt. The usual failure items are the various rubber "O" rings and the rubber parts in the diaphragm valve and solenoids. Repair kits are now available for these. In addition to the "O" rings at the air line connections, there are four that are under permanent compression sealing the airways between the two parts of the block at the join next to the inlet valve.  In time, these harden and start to leak, causing mysterious symptoms (see main valve block page).  Christian Khutz found replacement of the internal "o" rings made a huge difference.  "All the little mystery drops and adjustments are all gone. At any rate, highly recommend.  And the cost was south of $20 for maybe an hour worth of work".

Photo: Set of Valve Block and Air Spring O rings available from Rover Renovations for $12

Parts & Sources

Main parts needed for rebuild:
Exhaust Silencer: STC2762
Air hose from compressor to valve block: STC2760
Olive and nut for end repair of compressor hose: STC1472
O-Rings:
    2x STC2764 (4mm),
    9x STC2766 (6mm) (9 needed because port #6 has two in it). 
    4x STC 2768 (8mm).

Range Rover Owner Dennis Altman has gone to the trouble of assembling kits of complete O-ring sets (see photo above), as well as the valve repair kits and tubing, and making them conveniently and inexpensively  available to other owners via his Rover Renovations enterprise. A complete set of O-rings costs $12, with free shipping. If you prefer, he can also rebuild your own valve block for you with a 2-day turnaround. If you purchase from him please mention you came from Rangerovers.net!

Other Valve Block Parts (less likely to be needed):
Valve Block without solenoids: This has a separate part number (RVH100030) but does not seem to be readily available -- Land Rover prefers to sell you the complete assembly for about $900. Rover Renovations sells completely rebuilt units for about $300.
Valve Block Assembly: ANR3901 (complete with solenoid valves, diaphragm valve, pressure switch and wiring harness)
Pressure Switch: ANR3902
Solenoid Repair Kit: STC2761
Air line repair kit (6 mm) STC8580
Diahragm Valve repair kit: STC1803

Parts Sources:
Rover Renovations has rapidly become the main supplier of EAS parts for DIY Range Rover owners, including all parts needed for valve block rebuilds. Fellow Range Rover and Rangerovers.net contributor Dennis Altman became frustrated (like many of us) at the inability to buy less than the complete assemblies from the dealers and conventional parts sources. He went to the trouble of tracking down the sources of all the parts used in the EAS system, from the lowliest "O" ring to the air springs themselves. He now offers all these components for sale to fellow enhthusiasts through his Rover Renovations service. He also rebuilds the more expensive components (like valve blocks) and makes them available at a small fraction of the new price.


Illustrated Disassembly Details

The photos below, illustrating the dismantling process, were kindly supplied by Martin Hoey from his valve block disassembly and repair job. 

1
 2
Overall view of valve block from right hand side. Note assembly is composed of three separate blocks of aluminum.
Left of valve block showing driver module & compressor hose
3
 4
Rear view of valve block
 Front view of valve block
5
 6
Rear upside down view showing inlet/solenoid diaphragm valve block
Inlet/solenoid diaphragm valve block removed. Note spring connected to solenoid under block in this picture
8 7
Inlet/solenoid diaphragm valve block removed Solenoid Diaphragm valve in situ. This valve ensures that all air exhausted to atmosphere passes through the dryer.
10 11
Diaphragm kit Diaphragm removed from solenoid diaphragm valve
12 16
Close-up of damaged diaphragm Front end of main block with front block removed, exposing the three non-return valves.
18 20
Non-return valves Non-return valve block
9 19
Closeup of exposed front of main block main block with non-return valves removed, showing a score in block face Non-return valve closeup
13 14
Valve under solenoid for front left air spring Main block surface with front left solenoid valve removed
15 17
Underside of solenoid valve Solenoid for right rear air spring removed
22 21
Solenoid valve for right rear air spring removed exposing air passages in main block. Another view of diaphragm repair kit and the bolts holding the valve block together

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