Bodsy
Site Sponsor
Member Since: 06 Nov 2006
Location: In the Clubhouse
Posts: 21361
  
|
| How to - Front suspension valve block rebuild. |
|
I took the opportunity to disassemble my front valve block yesterday, so thought I'd video it if it helps anyone else in the future. 
I didn't add any lube and I didn't change any rubber seals as I didn't know I was going to do it until I got bored of changing my intercooler out.
The removal of the front valve block is described elsewhere on here, but essentially it's behind the bumper, access from the front drivers (UK) wheel arch liner. Bodsys Brake Bible
D4/D3 Remote FBH heat kits
BAS Remaps/ EGR Blank
Transmission Flush
Software updates/enabling
Clock/ SNOTM /3Flash / 4x4Info /BT Update /Service Reset/Error Codes / Gearbox Reset
See It Here
|
 7th Aug 2015 11:18 am |
|
|
maplecottage
Member Since: 01 Feb 2011
Location: Norfolk
Posts: 3171
|
|
| 7th Aug 2015 12:22 pm |
|
|
parrafin23
Member Since: 04 Dec 2011
Location: Buskeud
Posts: 678
|
Great you put that vid up Bodsy, I ahve a sinkin front on mine, and I have to haev a look at the valve block soon. Can I ask you to replace one thing before makin another video?
get a HD cam.. The video quality was not the best i have seen.
But please do more of these vids Bodsy. We all love'em
Mr.P
|
| 7th Aug 2015 3:39 pm |
|
|
Bodsy
Site Sponsor
Member Since: 06 Nov 2006
Location: In the Clubhouse
Posts: 21361
|
For some reason, it wouldn't let me upload in better quality.
If you have a HD cam you want to send my way, feel free, it was just a quick video on the iPad. Bodsys Brake Bible
D4/D3 Remote FBH heat kits
BAS Remaps/ EGR Blank
Transmission Flush
Software updates/enabling
Clock/ SNOTM /3Flash / 4x4Info /BT Update /Service Reset/Error Codes / Gearbox Reset
See It Here
|
| 7th Aug 2015 4:01 pm |
|
|
MrH
Member Since: 08 Aug 2007
Location: lost in the forest
Posts: 7754
|
Thanks for this Bodsy. 
I replaced my front valve block with a used one from MMJ but still got the front suspension sagging overnight, so now that I found this I'll take apart the originalc one and check for white dust LRs are a fond memory, apart from the maintenance.
|
| 17th Jan 2016 6:38 pm |
|
|
griff488
Member Since: 21 Feb 2013
Location: Tamworth Staffs
Posts: 277
|
What lube would you reccommend for the seals please? 2004 Disco 3 TDV6 SE
1997 300TDI Disco (Rust In Peace)
Swift Accord 590
iCarsoft i930
|
| 20th Mar 2016 5:30 pm |
|
|
MrH
Member Since: 08 Aug 2007
Location: lost in the forest
Posts: 7754
|
I'd use a light silicon based grease.
Turns out my valve block was clean as a whistle inside, so back to square one trying to diagnose the cause of the overnight sag  LRs are a fond memory, apart from the maintenance.
|
| 20th Mar 2016 5:44 pm |
|
|
Alwaysthirsty
Member Since: 16 Jan 2023
Location: Cape Town
Posts: 26
  
|
Hi Bodsy, Just bought a 260K/kms here in SA, it's a D4 2012 SE V8, I have the sinking front end overnight can I ask a stupid question?
What are we looking for here cleaning the block, a loose fitting, crap in a line?
Would love a quick heads up on where to start with this issue..
TIA
White dust?? Sounds well dodgy 
|
| 30th Jan 2023 10:09 am |
|
|
Pete K
Member Since: 15 Jan 2016
Location: GL
Posts: 10363
 
|
White dust comes from compressor dryer
|
| 30th Jan 2023 12:12 pm |
|
|
Alwaysthirsty
Member Since: 16 Jan 2023
Location: Cape Town
Posts: 26
|
It helps to actually listen to the video not just watch it
|
| 30th Jan 2023 12:37 pm |
|
|
CAR973
Member Since: 30 Aug 2019
Location: Dorset
Posts: 3
|
I left mine overnight to see which corner or end was the leaky problem and only one front corner had dropped 1cm. Replaced the O-rings in the front block (4x4airseals.com) and it seems to have done the job.
If nothing else, the old rings were a bit crusty, worn and compressed so I probably need to do the other blocks at some stage.
|
| 2nd Feb 2023 8:54 am |
|
|
Alwaysthirsty
Member Since: 16 Jan 2023
Location: Cape Town
Posts: 26
|
Thanks CAR973, I had the guys at TwinLandy, CapeTown, who have a solid reputation, look at it yesterday they think the Hitachi compressor is gone, not sure how the car is pumping itself back up if that is the issue??
I have asked them to look at the front block first as that looks like the most likely offender, he also reckons the front left sensor could be to blame. I'm learning as we go, never had an issue on the old D3.
|
| 2nd Feb 2023 9:10 am |
|
|
CAR973
Member Since: 30 Aug 2019
Location: Dorset
Posts: 3
|
Thirsty, my 2008 D3 is about to turn 100k miles without any significant air problems. Admittedly it's been about 18 months that the car has been dropping but self-levelling made the problem look much worse than it was. Photos from my security camera showed the self-levelling in action overnight.
Finding no air leaks is frustrating but possibly a good outcome and in my case the soapy water test didn't reveal anything. Like you, my car raised itself each morning and wouldn't drop while using it through the day - only overnight.
I would say it's more likely to be a leaky union or inside one of the valve blocks. It's not difficult to do the O-rings if you can get hold of a set. There's something like 17 o-rings to replace including the three Voss connectors for the front and rear blocks - far better to refurb the OEM block than replace it with some cheap knock-off from China.
At least if you do the front block you either eliminate it as the problem or it fixes it and the cost is probably less than a tray of Castle if you can do it yourself.
|
| 2nd Feb 2023 10:05 am |
|
|
Alwaysthirsty
Member Since: 16 Jan 2023
Location: Cape Town
Posts: 26
|
Ha Ha, one tray of Castle 
Ill buy the O ring kit for sure, my issue was the suspension warning is popping up, funny thing is the fault codes were not there when the guy at Twin Landy plugged his machine in, I have booked her in nedt Tuesday so Ill let you know what the diagnosis is. Ex D3 2008 HSE owner in UK, a part of the family let go to the Autotrader orphanage 
|
| 2nd Feb 2023 10:44 am |
|
|
CAR973
Member Since: 30 Aug 2019
Location: Dorset
Posts: 3
|
The similarity ends with the dash warning light - I didn't get that so perhaps you've got more than one issue And that's the challenge with running a D3 or D4 in UK..... unless you can pinpoint and fix most things yourself, they can really bite into the beer budget. Thank goodness for this forum.
Another youtube guide on how to fit the 14 internal o-rings (yes, 14!) adds a bit more detail and there's a part 2 on how to reconnect the Voss unions.
Good luck!
|
| 2nd Feb 2023 11:07 am |
|
|
