ACE - high pressure pipes fracturing

ACE - HIGH PRESSURE PIPES FRACTURING

Model

Discovery II

Reference

Recall action 203

Bulletin text

RECALL ACTION BULLETIN

Circulation: X Indicates to whom this information should be circulated SERVICE MANAGER X SERVICE RECEPTION PARTS MANAGER WARRANTY MANAGER

Discovery Series II with factory fitted ACE system

Build date range

PROBLEM:

ACE - HIGH PRESSURE PIPES FRACTURING

CAUSE:

Land Rover have identified a concern associated with ACE system high pressure pipes fitted to Discovery Series II models. The pipes may, under certain conditions fracture and leak fluid, which would revert the vehicle handling back to non-ACE operation. This would be progressively accompanied by amber and red warning lights on the instrument console. In extreme circumstances should the vehicle continue to be driven and sufficient fluid be expelled into the engine bay and an ignition source is present the fluid could ignite.

ACTION:

To protect the long term integrity of the ACE system, Land Rover are implementing Recall action on all Discovery Series II models with factory fitted ACE within the affected VIN range. All Discovery Series II models within the affected VIN range fitted with ACE will require the high pressure pipes to be replaced with quality assured parts. All vehicles currently used as demonstrators, held in stock, showroom and used vehicles must have this work carried out prior to customer despatch of the vehicle.

PROCEDURE

CARE POINT: The ACE system is extremely sensitive to contamination. The vehicle must be pressure washed around the length of the high pressure pipe and allowed to dry prior to commencing the pipe change.

1. Secure the vehicle on a flat level surface in gear/park with the handbrake on and ignition off. 2. Raise the vehicle to allow removal of the front right wheel. 3. Remove the under belly NVH tray.

SERVICE ACTION BULLETIN No: A/B/D203

EN Bull. N o : A/B/D203

AFFECTED RANGE:

YA233202 to YA258267

13 July 1999 to 13 December 1999

Rover Group 2000

4. Remove the 2 way isolator and bracket from the chassis cross member below the radiator, retain the bracket for re-fitment. CARE POINT: Whenever a pipe bracket is removed its orientation should be noted to ensure that it is fitted the correct way around, otherwise the system refinement will be adversely affected. 5. From the front of the valve block (aluminium unit on chassis side member) remove the two 13mm securing nuts. 6. CARE POINT: During the next operation it is important that the four pipes remain in the valve block whilst the keeper plate is prised away. Gently prise the keeper plate 5mm away from the valve block ensuring at this stage all pipes remain in the valve block. Squeeze the nylon collets together on all four pipes so that the keeper plate can be moved further away from the valve block again ensuring that the pipes remain in the block, ease the keeper plate along the pipes. 7. Remove the collet from the bottom pipe in the keeper plate, this pipe is denoted with a label with the letter ‘P’, the letter ‘P’ is also stamped on the face of the keeper plate, discard this collet. Loosely fit the keeper plate to prevent the remaining three pipes from coming out of the valve block and temporarily secure using two of the 13mm nuts. 8. Lower the chassis onto a support allowing the front right hub to travel down to full rebound condition. 9. Remove the 4 way isolator and bracket from the chassis side member. Remove the 4 way isolator on the damper turret, this isolator is accessible from within the engine bay, retain all parts for refitment. 10. Remove the plastic shield from the wheel arch behind the ACE actuator by removing the three screws. 11. Cut away the glued 2 way isolator supporting the rigid pipes, and discard. 12. Cut either side of the ‘P’ pipe on the glued 4 way isolator mount above the chassis outrigger that houses the ACE system rigid pipes, to allow later removal. 13. Cut the steel section of the high pressure pipe (the 2nd from bottom) behind the damper turret in the wheel arch, and bend down to prevent metal particles flowing toward the valve block. NOTE: The best way of cutting the pipes is with a large pair of ‘Tin snips’. 14. Fully remove pipe ‘P’ from the keeper plate still ensuring that the other three pipes remain in position within the valve block. 15. Allow the contents of the pipe to drain out, and remove the steel section through the wheel arch. 16. Cut the steel section of the high pressure pipe (the uppermost of the pair) in front of the damper turret. 17. Drain and remove the intermediate section at the damper tower.

SERVICE ACTION BULLETIN No: A/B/D203
Rover Group 2000

18. Remove the 19mm banjo bolt and pipe from the pump outlet to allow further draining. 19. Discard the two seals from the banjo bolt. 20. Remove the flexible section of pipe from the vehicle and discard. 21. CARE POINT: When fitting the new pipes ensure that the protective end caps remain present at all times until they are connected. 22. Feed the new flexible pipe through the inner wing, remove the protective cap and using new washers secure the banjo end of the pipe to the pump, torque banjo to 27 to 30 Nm. 23. Continue to feed the pipe through until the rigid capped end of the pipe lies in front of the damper turret. 24. Gently bend the inner wing behind the damper turret (where the flexible brake pipes are fixed) away from the chassis. 25. Remove the electrical harness from the damper turret to ease fitting of the new pipe. 26. CARE POINT: When fitting the new pipe ensure that the accelerometer wiring harness is not dislodged. 27. Insert the rigid section of pipe from the wheel arch, above the outrigger (inboard of the body mount). 28. Slide the capped end of the new rigid pipe beyond the valve block and then route the front end inside the inner wing, and inboard of the damper tower. 29. When the end of the pipe is level with the front of the valve block remove the end cap, manoeuvre pipe ‘P’ between pipes ‘A’ and ‘T’,check to ensure that the pipe is correctly routed over its entire length. 30. Remove the keeper plate again, and feed the new pipe ‘P’ through. 31. Ensure that all pipes are in the keeper plate noting that the other three pipes should still be in position, slide the new collet ANR6700K over the ridge on the ‘P’ pipe with the ‘ears’ of the collet facing the front of the vehicle, close the collet over the pipe. 32. Slide the keeper plate down the pipes and over all four collets ensuring that all the ‘ears’ on the four collets are latched in the keeper plate. Refit the keeper plate nuts and tighten to 19 to 25 Nm. 33. Remove the two rigid pipe union protective caps and loosely fasten the two pipes together.

SERVICE ACTION BULLETIN No: A/B/D203
Rover Group 2000

34. Fit the new 4 way isolator mount above the outrigger, behind the old isolator, apply super glue to both halves of the isolator and press together. 35. Fit the new 2 way isolator above the chassis rail and glue the two halves together using super glue, ensuring that the pipes do not touch the steering box on right-hand drive vehicles. 36. CARE POINT: All pipe mounting brackets must be fitted the same way round as when removed. 37. Refit both pipes into the 2 way isolator and bracket on the front cross member under the radiator, and Torque to 7 to 10 Nm. 38. Replace the under belly tray. 39. Refit the 4 way isolator and bracket on the damper tower and the chassis side member ensuring that all four pipes are in the isolator recesses, secure the brackets in position. 40. Push the inner wing section back into position and replace the electrical harness ensuring no fouls to the ACE pipes. 41. Tighten rigid pipe union to 23 to 27Nm. 42. Refit the plastic shield and secure in place with the three screws. 43. Replace the road wheel, tighten to the correct torque, and lower the vehicle. 44. Check the ACE reservoir fluid level and top up as necessary with Texaco ‘Cold climate PAS fluid 14315’. 45. Make a final check over the whole length of the rigid pipes to ensure that there are now ‘fouls’ in the pipe runs. 46. Start the engine and allow the vehicle to idle for one minute checking for system leaks. 47. Check and top up the ACE system reservoir. 48. Endorse the service record book. 49. Apply a dab of white paint to the ACE fluid reservoir cap as a visual indication that this work has been completed.

PARTS INFORMATION:

RQB100290K High pressure pipe - Diesel models front 1 off RQB100250K High pressure pipe - Petrol models front 1 off RQB100260K High pressure pipe - Rear 1 off (Common to both Petrol and Diesel models)

ANR6703K Isolator 4 way 1 off ANR6704K Isolator 2 way 1 off ANR6700K Collet 1 off RYF100420 Sealing washers - pump 2 off STC50519 Cold climate PAS fluid 14315’. Super glue - Locally sourced

WARRANTY CLAIMS:

SERVICE ACTION BULLETIN No: A/B/D203
Rover Group 2000

UK - Complaint code A203 Option code A = 00.15 hours - Inspection Option code B = 02.00 hours - Inspection and replace Petrol models only Option code C = 02.00 hours - Inspection and replace Diesel models only

UK Note: An allowance of £5.00 can be claimed for fluid using ZZZ1.

USA/Canada - Complaint code B203 60.60.89/30 - 00.15 hour - Inspect only 60.60.89/27 - 02.00 hour

Europe/Rest of World - Complaint code D203 60.60.89/30 - 00.15 hour - Inspect only 60.60.89/27 - 02.00 hour

USA/Canada/ Europe/Rest of World: An material allowance for fluid has been included in the material allowance upper limit to the value of £5.00 UK Sterling.

The vehicle VIN range includes those vehicles that are not fitted with ACE, therefore an inspection claim must be submitted to remove the vehicle from the warranty file.

Some vehicles have been reworked at Land Rover and will already have service pipes fitted to them, these vehicles will require no further action but an inspection must be carried out on the vehicles and a claim for inspection submitted to remove the vehicles from the warranty database.

ADDITIONAL INFORMATION: 1. If either pipes ‘A’ or ‘B’ are removed from the valve block, a system response test must be successfully carried out using Testbook prior to the vehicle being released. 2. This bulletin refers to changing the high pressure pipe without there having been a component failure, therefore the ACE valve block filter is not changed. In all cases where the hose is being changed as a result of a failure, a new filter must be fitted.

SERVICE ACTION BULLETIN No: A/B/D203
Rover Group 2000