Coolant leakage - cylinder head gasket failure

COOLANT LEAKAGE - CYLINDER HEAD GASKET FAILURE

Model

Freelander

Affected vehicles

WA 600000 to YA 699999 YA 500000 to 1A 599999 All K1.8 Freelander in VIN ranges: 1A 300000 to 1A 324161

Date

2001-08-22

Reference

Bulletin 0026, CDS ref L8665bu

Bulletin text

Freelander

AFFECTED RANGE:

All K1.8 Freelander in VIN ranges: WA 600000 to YA 699999 YA 500000 to 1A 599999 1A 300000 to 1A 324161

PROBLEM:

COOLANT LEAKAGE - CYLINDER HEAD GASKET FAILURE The customer may complain of: • Difficulty in maintaining coolant level. • Engine oil in coolant or coolant in engine oil. • Visible coolant leakage at cylinder head joint face. • Engine overheating.

CAUSE:

Failure of the cylinder head gasket, due to insufficient coolant flow during engine warm up. NOTE: A new design of cylinder head gasket and remotely mounted thermostat has been introduced into production at VIN 1A 324162.

ACTION:

Preliminary Checks:

• Carry out cooling system pressure test. • Should there be any evidence of coolant leakage from the inlet manifold gasket, refer to Technical Bulletin 0002 - INLET MANIFOLD GASKET - COOLANT LEAK. • In the event that coolant leakage from the cylinder head gasket is confirmed, refer to the following procedure to replace the cylinder head gasket and modify the thermostat installation. Rectification Procedure: 1. Replace cylinder head gasket and dowels as detailed in Workshop Manual repair number 12.29.02, noting the following: Take special care not to damage the cylinder block sealing face when removing the plastic dowels. Replace the existing dowels with new dowels from gasket kit LVB000320L. Ensure that the fitted height of the new dowels is between 10 and 11mm.

Bulletin N o : 0026

2. Remove engine thermostat and rubber seal. Refer to Workshop Manual repair number 26.45.09, (pre 2001 MY) or 26.45.01, (2001 MY onwards).

3. Replace thermostat with thermostat blanking plate PEL000040 and reassemble using new rubber seal PEF10010.

4. Remove top and bottom coolant hoses.

5. Replace hoses with new hose assembly PCH001190 which incorporates the new thermostat, ‘A’ in illustration. Hose connections ‘B’ in illustration go to the original top hose connection points. Hose connections ‘C’ in illustration go to the original bottom hose connection points.

6. Refill cooling system with new coolant. Ensure that system is correctly bled and free from air pockets. Refer to Technical Bulletin 0004 - OVERHEATING - AIR IN COOLING SYSTEM

PARTS INFORMATION:

Part Number Description LVB000320L Cylinder head gasket kit PEL000040 Thermostat blanking plate PEF10010 Thermostat seal PCH001190 Hose assembly (including thermostat)

WARRANTY CLAIMS: Use Complaint Code: 1S6N

Use S.R.O.: 12.29.02 Head gasket renew - no air conditioning - up to 2000 MY Time allowance: 4.60 Hrs

Use S.R.O.: 12.29.02 Head gasket renew - no air conditioning - from 2001 MY on Time allowance: 4.80 Hrs

Use S.R.O.: 12.29.02/20 Head gasket renew - with air conditioning - up to 2000 MY Time allowance: 5.00 Hrs

Use S.R.O.: 12.29.02/20 Head gasket renew - with air conditioning - from 2001 MY on Time allowance: 4.70 Hrs

Use S.R.O.: 12.29.89/44 Thermostat blanking plate and hose assembly Time allowance: 0.50 Hrs