Idler pulley - premature failure

IDLER PULLEY - PREMATURE FAILURE

Model

Discovery II

Reference

Recall action 216(2)

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 V8 Petrol All models

Range Rover V8 Petrol

Build date

PROBLEM:

IDLER PULLEY - PREMATURE FAILURE

CAUSE:

The engine idler pulley fitted to Range Rover V8/Discovery series II V8 Petrol models cannot accommodate the additional drive belt loading that is being experienced on ‘Thor’ engine derivatives.

Failure of the pulley will cause drive belt damage, which will result in the loss of Power steering, charging circuit, Air conditioning and cooling system.

ACTION:

To protect the long term integrity of the idler pulley, an all new pulley, manufactured from steel has been introduced into production. To ensure our customers receive the long term benefits of this new part, Land Rover are extending Recall Action on all Range Rover V8 and Discovery Series II V8 models within the affected VIN range. Vehicles that are only fitted with power steering are not affected by this action.

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.

This campaign supercedes A/B/D369.

PROCEDURE

• Refer to the workshop manual for instructions on drive belt removal. • Remove the idler pulley as identified by the arrow in illustration fig 1. • Fit new idler pulley PQR101150K, ensure that it rotates freely and that the inner bore of the pulley does not contact the cast webs of its mounting. Should the pulley contact the cast webs carefully fettle the web to provide clearance, tighten the pulley bolt to 50 Nm. • Ensure the belt is correctly located in all pulley grooves, apply clockwise pressure to the tensioner pulley to tension the belt and tighten the tensioner pulley to 45 Nm.

RECALL ACTION BULLETIN No: A/B/D216 Issue 2

EN Bull. N o : A/B/D216

AFFECTED RANGE:

XA200611 to YA277051 XA900000 to XA907212

XA410482 to YA443347

27 August 1998 to 03 April 2000

Land Rover 2000

• Apply a white paint identification to the pulley bolt head as a visual identification that this work has been completed. • Endorse the service record book. • Remove the idler pulley as identified by the arrow in the illustrations below.

Key to illustrations:

Fig 1 - Discovery Series II Air conditioning/ACE & Power Assisted Steering

Fig 2 - Discovery Series II Air conditioning & Power Assisted Steering

Fig 3 - Discovery Series II ACE & Power Assisted Steering

Fig 4 - Range Rover Air conditioning & Power Assisted Steering

PARTS INFORMATION:

PQR101150K Heavy duty idler pulley - 1 off

RECALL ACTION BULLETIN No: A/B/D216 Issue 2
Land Rover 2000

WARRANTY CLAIMS:

UK only: Complaint code A216 Option code A = 00.50 hour - Replace pulley - Discovery only Option code B = 00.40 hour - Replace pulley - Range Rover only

USA/Canada: Complaint code B216 57.20.08 = 00.50 hour - Replace pulley - Discovery only 57.20.08 = 00.40 hour - Replace pulley - Range Rover only

Europe/Rest of World: Complaint code D216 57.20.08 = 00.50 hour - Replace pulley - Discovery only 57.20.08 = 00.40 hour - Replace pulley - Range Rover only

RECALL ACTION BULLETIN No: A/B/D216 Issue 2
Land Rover 2000