Durability of cooling system hoses

DURABILITY OF COOLING SYSTEM HOSES

Model

Range Rover P38

Reference

Recall action 219

Bulletin text

RECALL ACTION BULLETIN

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

Range Rover V8 Petrol (Cooling Hoses)

Build date range

PROBLEM:

DURABILITY OF COOLING SYSTEM HOSES

CAUSE:

Land Rover has received a number of reports detailing premature failure of cooling system hoses. In certain cases a hose failure may cause a roadside breakdown. It is important that all traces of expelled coolant are removed since if allowed to remain on hot engine components can result in evaporation of the water content, thus leaving an artificially high concentration level of anti-freeze, which in extreme conditions is both corrosive and, flammable.

Land Rover, as part of a continuous improvement programme, has introduced coolant hoses manufactured from modified materials into vehicle build. These quality assured parts will be offered to current Range Rover owners free of charge.

This action has resulted in significant improvements to parts quality. In order that our customers benefit from the introduction of the new materials Land Rover are contacting customers to carry out a recall to replace all existing hoses for quality assured parts.

ACTION:

All vehicles must be reworked fitting new parts. Vehicles that appear in the VIN range that are currently held in stock, showroom, demonstrator or used vehicles should be reworked prior to customer receipt.

**IMPORTANT NOTE: THE FOLLOWING THREE PARAGRAPHS MUST BE READ PRIOR TO COMMENCING ANY WORK ON THESE VEHICLES.

This campaign supercedes campaign A/D312. It should be noted that a number of vehicles affected by A/D312, have still not been reworked. It is important to check every vehicle to ensure that it either has the additional clips applied to the expansion hoses at the expansion tank, or in the case of automatic models, has the modified and re-routed gearbox breather pipe to the inner wing. Should either of these two conditions not be present it will indicate that additional work will be required to include those options not previously carried out.

RECALL ACTION BULLETIN No: A/D219

EN Bull. N o : A/D219

AFFECTED RANGE:

MA300000 to WA410481

June 1994 to August 1998

Land Rover 2000

All vehicles from MA300000 to WA410481 will require the fitment of new hoses but some vehicles within this range that did not benefit from A/D312 may require the following additional parts; washer hose, gearbox breather, fluid checks and cleaning of earth/ground points. Should this be the case, reference must be made to the various options listed both in the parts and warranty section of this bulletin. The rework instructions for these additional items have been extracted from A/D312 and are included in this bulletin.

IMPORTANT NOTE: The top hose included in the hose kit PDK000020K must be discarded and rendered un-useable, ie cut in half and hose PCH001490K used in its place. The new hose has been identified with a green timing mark on the end of the hose. ON NO ACCOUNT MUST THE TOP HOSE BE USED FROM THE KIT.

PROCEDURE

New Cooling System Hoses - MA300000 through to WA410481

Remove expansion tank filler cap. Drain coolant from system into a clean container by removing the radiator drain plug. Refit and secure the drain plug to 6 Nm maximum.

The new hoses are supplied in a kit. The thermostat is not included in the kit as it should not need replacing.

Remove the following hoses with all clips and discard. NOTE: The thermostat and hose assembly must be removed as an assembly with hoses attached. Do not unclip hoses from the thermostat as this will be used as the pattern to ensure that new hoses are fitted in the correct orientation. The hoses are identified to ensure that they correctly orientated at the thermostat, special attention should be paid to the timing marks on the hoses and raised timing marks moulded into the case of the thermostat. REMOVE ONE HOSE AT A TIME.

1. Heater inlet 2. Heater return 3. Heater return to thermostat) 4. Bypass hose 5. Radiator hose to thermostat 6. Bypass hose to thermostat 7. Bottom hose 8. Top hose 9. Throttle body heater - feed 10. Throttle body heater return 11. Radiator bleed line

IMPORTANT NOTE: The spring band clip fitted to the inlet manifold end of the heater inlet hose, (item 1 on the illustration opposite), must be removed from the hose and fitted to the stub pipe first, as it will not pass over the stub pipe raised bead, the hose should then be fitted and the clip manoeuvered back over the hose.

RECALL ACTION BULLETIN No: A/D219
Land Rover 2000

The hose kit incorporates two small ‘cobra’ clips which were originally included to be fitted to the throttle body heater feed hose (item 9 on the illustration above), access for fitting these clips is very restricted, therefore the ‘cobra’ clips must be discarded and the worm drive clips already fitted to the displaced hose must be reused.

Hose fitting CARE POINTS

• Attention must be paid to any hose ‘timing’ marks to ensure that the new hoses are fitted in their correct orientation. • All stub pipes are to be thoroughly cleaned, dry and be free of corrosion prior to fitment of the new hose. It is essential that an appropriate tool is used to fit the clip to avoid damage. • CAUTION: Lubrication must NOT be used to aid fitment of the new hoses. • Check that all hoses are clear of moving parts and that there are no kinks in the hoses, any clips removed are to be replaced. • Check that the stub into the expansion tank for the radiator bleed line is clear (by blowing through). If blocked clean as required.

New radiator to expansion tank bleed line

1. Fit clip DYC101410 to bracket PYH100390 and fit to the front fixing of the underbonnet fuse box, using the original fixing, illustration C. 2. Remove the battery box cover for access. 3. Drill a 6.3mm hole in the front battery clamp bracket 48mm from the front fixing hole, apply wax to the drilled hole to prevent corrosion, insert new clip PYC102830 in the underside of the battery clamp bracket, illustration A. 4. Install the new radiator to expansion tank hose following the routing as shown in the illustration opposite.

RECALL ACTION BULLETIN No: A/D219
Land Rover 2000

5. Apply a tie wrap around the bleed line, feeding the tie wrap into the rear fixing hole of the fuse box to encapsulate the bleed line, do not overtighten the tie wrap, illustration B. The tie wrap must be directed to the front of the vehicle, directed to the rear of the vehicle will result in the bleed line run being shortened and ultimately fouling on the battery box cover. 6. Refit the battery box cover. 7. Check the routing of the bleed line to ensure there are no kinks and that there is no contact with the inner wing or radiator mounting points and battery box cover. 8. Refill the cooling system using the coolant previously drained off. Top up to workshop manual procedure 26.10.01 using Land Rover approved antifreeze/water mixed 50/50% 9. When engine is hot inspect for leaks

The following operations, washer hose, gearbox breather, fluid checks and cleaning of earth/ground points are to be carried out on those vehicles that did not benefit from previous campaign A/D312.

Washer System Hose/Non Return Valve MA300190 to WA402293

1. Disconnect the washer tube from the bonnet washer jet. 2. Compress the washer tube clip and slide the clip down the large washer tube to aid disconnection of the washer tube from the ‘harness’ connection. 3. Disconnect the tube where it attaches to the ‘harness’ tube. 4. Cut 10 mm from the end of the ‘harness’ tube, this will remove the deformed end of the ‘harness tube’ and provide a good joint upon connection of the new tube. 5. Unclip the washer tube clip at the bulkhead, this action will require the use of a screw driver to release the barb which attaches the clip to the ‘T’ stud on the bulkhead. 6. Connect the end of the new washer tube (the end where the non return valve is located), onto the ‘harness’, tube. 7. Compress the washer tube clip and slide it along the ‘harness’ tube to within 2 mm of the end of the harness tube and secure in place. 8. Route the new washer tube behind the expansion tank reservoir and loop back clipping the washer tube clip to the bulkhead ‘T’ stud so that the tube is pointing to the side of the vehicle. 9. Connect the remaining end of the tube to the bonnet washer jet. 10. Ensure all connections are secure, that there are no kinks in the tube and that the operation of the washer system operates without fluid leaks.

RECALL ACTION BULLETIN No: A/D219
Land Rover 2000

Gearbox Breather Pipe - MA300190 to WA402293 - Automatic derivatives only

1. In order to ensure that the banjo bolt remains in position on the new breather, check to determine that the plastic cap on the banjo is firmly in place. Also check that there are two copper sealing washers, one under the head of the banjo bolt, the other beneath the plastic cap. 2. Place vehicle on a hydraulic ramp and open bonnet. 3. It should be noted that the new breather is cranked, standing facing the front of the vehicle. The crank in the pipe must be routed to the drivers side of the vehicle (Left hand drive vehicles) and to the passenger side (Right hand drive vehicles). Feed the banjo end of the new breather down between the rear of the of the engine and bulkhead adjacent to Number 6 plug lead until it stops on the torque converter housing. 4. Raise the vehicle on the hydraulic ramp. 5. From under the vehicle retrieve the new breather pipe from on top of the automatic gearbox. Carefully pull the breather rearwards, following the route of the oil cooler pipes and above and behind the kickdown cable feed the new breather towards the existing gearbox breather pipe. 6. Clean the area around the automatic gearbox existing breather banjo bolt prior to removal. 7. Remove existing banjo connection from the gearbox. 8. Fit new breather pipe to the gearbox, tightening the banjo to 14 Nm. 9. Remove the tie wrap securing the old breather pipe to the transfer gearbox breather pipe. Apply a new tie wrap (locally sourced) to the same position now encapsulating the new breather pipe to the transfer gearbox breather pipe. Cut the banjo connection from the old pipe to enable the pipe to be pulled free from the bonnet area of the vehicle. 10. Push the old breather pipe upwards to enable the breather pipe to be identified from the transfer gearbox breather within the bonnet area of the vehicle. 11. Secure the breather pipe to the top of the torque converter housing utilising the spring clip on the pipe. Firmly push the clip onto the uppermost stiffener rib.

RECALL ACTION BULLETIN No: A/D219
Land Rover 2000

12. Lower ramp. From within the bonnet area, feed the free end of the breather pipe below the throttle cable closely following the line of the bulkhead positioning the pipe behind components that are situated in this area. 13. Remove the two bolts securing the purge canister to provide access to the inner wing area.

DO NOT REMOVE HOSES FROM THE PURGE CANISTER TO AID ASSEMBLY.

14. Feed the breather behind the purge canister and direct the pipe down to the inner wing area adjacent to the bulkhead. 15. Measure 180mm (7.5 inches) from the tip of the breather pipe snap end fitting. Remove and cut off breather pipe end. 16. Cut the breather pipe at a 45 ° degree angle as shown in the illustration opposite.

CAUTION: Ensure that the angle of the cut is made so that the opening is oriented toward the inner wing.

A = Bulkhead clip B = Breather pipe, cut to 45 ° degree angle C = Engine bay harness D = Inner wing valance E = Evaps pipe (Where fitted)

17. Slit the top side of the pipe back about 15 to 20 mm (5/8 to ¾ inch) as illustrated opposite. 18. Position, so that modified end of the breather tube is approximately 25mm (1 inch) from the under-hood harness located in the corner of the inner wing area.

CAUTION: It is important that the end of the breather tube has 25mm (1 inch) clearance from the electrical harness to ensure that there is no harness damage or any potential for contact with the breather tube. 19. Secure the pipe to the two bulkhead mounted pipe clips. 20. Refit the purge canister. 21. After the breather has been fitted a final check of the breather routing should be undertaken to ensure that there are no kinks or deformations in the breather caused during the installation process.

RECALL ACTION BULLETIN No: A/D219
Land Rover 2000

Check Gearbox Fluid Level - MA300190 to WA402293 - Automatic derivatives only

IMPORTANT NOTE: Under normal circumstances automatic gearbox fluid level should be checked when the fluid is ‘COLD’, normally when the vehicle has stood for approximately 6 to 8 hours. Should this be the case the check procedure identified in the workshop manual should be followed taking careful note of the ‘COLD LEVEL’ detail below. If the fluid is ‘HOT’ the same check procedure should be followed but taking careful note of the ‘HOT LEVEL’ detail.

NOTE: If the level is above the MIN COLD mark on the dipstick additional fluid is NOT required. If the fluid is above ‘MAXIMUM HOT’ level (hot) or ‘MAXIMUM COLD’ level (cold), this will indicate that the gearbox has been overfilled and the excess fluid MUST BE DRAINED OFF.

CAUTION: The ‘HOT’ measurement level specified in this procedure is the MAXIMUM level allowable with a fully hot engine/gearbox. • Always check the transmission fluid level under either fully ‘HOT’ or fully ‘COLD’ conditions. • DO NOT OVERFILL

AUTOMATIC TRANSMISSION FLUID LEVEL MEASUREMENT PROCEDURE

1. Position the vehicle on a level surface with the parking brake applied and the transmission in Park. 2. Apply the foot brake and start the engine.

3. WARNING: Ensure that the foot brake and park brake are firmly applied during the following procedure: 4. With the foot brake still applied, move the gear shift lever slowly through each gear position starting from Park. (P
R
N
D
3
2
1) 5. Return the gear shift lever to Neutral (N) and leave the engine running. 6. Remove the transmission dipstick and wipe clean. 7. Insert the clean dipstick into the gearbox and ensure that it is pushed in completely.

COLD LEVEL CHECK: After checking the fluid level if the fluid is found to be above the ‘MAX COLD’ level on the dipstick, excess fluid MUST be drained off. If the fluid level is above the ‘MIN COLD’ .level there is no requirement to add additional fluid.

HOT LEVEL CHECK

CAUTION: If the engine is ‘HOT’ the MAXIMUM oil level is at 19 mm (0.750 in) above the upper maximum cold indicator hole/marking on the dipstick. This location indicates the MAXIMUM HOT transmission oil level.

RECALL ACTION BULLETIN No: A/D219
Land Rover 2000

If the fluid level hot, is above the ‘MAX HOT’ level, fluid must be drained off. If it is above the ‘MIN COLD’ level, there is no requirement to add fluid.

Check Transfer Gearbox Fluid Level - MA300190 to WA402293

1. Ensure vehicle is on level ground 2. Place a drain tray under the transfer gearbox. 3. Thoroughly clean the area around the filler level plug. 4. Remove the filler level plug and check that no oil is expelled from the level plug hole which will indicate that the gearbox has been overfilled. Allow any excess oil to drain. 5. Clean filler level plug and apply Hylomar sealant to the plug threads. 6. Refit the level plug and tighten to 30Nm.

Ground Cables - MA300190 to WA402293

Remove and clean the main ground cable eyelets at the chassis post, ensuring they are free from contaminants. Apply a petroleum jelly/grease to the eyelets and resecure, tighten to 8 to 12 Nm.

Remove and clean the main engine ground cable eyelets at the engine block ensuring they are free from contaminants. Apply a petroleum jelly/grease to the eyelets and re-secure, tighten to 8 to 12 Nm.

The main body ground is via the engine ground cable, the fixing point of which is located below the under bonnet fuse box.

Remove and check that this contamination, clean as necessary. Apply petroleum jelly/grease to the terminal, tighten to 8 to 12Nm.

The engine harness ground point is located below the under bonnet fuse box. Remove and check that this point is free from contamination, clean as necessary. Apply petroleum jelly/grease to the terminal, tighten to 8 to 12Nm.

RECALL ACTION BULLETIN No: A/D219

point is free from

Land Rover 2000

Finally: Inspect the underbonnet area and clean up any fluids that may have been expelled during this vehicle rework.

ROAD TEST THE VEHICLE, ONCE BACK AT THE WORKSHOP OBSERVE ALL NEW HOSES FOR LEAKS AND SECURITY

APPLY A WHITE PAINT MARK TO THE FORWARD ROCKER COVER BOLT RECESS (IDENTIFIED BY THE ARROW ON THE ILLUSTRATION OPPOSITE) TO PROVIDE VISUAL EVIDENCE THAT THIS WORK HAS BEEN COMPLETED AND TO PREVENT THIS WORK BEING CARRIED OUT AGAIN.

ENDORSE THE SERVICE RECORD BOOK TO IDENTIFY THAT THIS WORK HAS BEEN COMPLETED.

PARTS INFORMATION:

IMPORTANT NOTE: The top hose included in the hose kit PDK000020K must be discarded and rendered un-useable, ie cut in half and hose PCH001490K used in its place. The new hose has been identified with a green timing mark on the end of the hose. ON NO ACCOUNT MUST THE TOP HOSE BE USED FROM THE KIT.

MA300000 to WA410481 Automatic and Manual models PDK000020K - Hose kit - 1 off PCH001490K - Top hose - 1 off

MA300000 to WA402293 Automatic models only (For vehicles not reworked as part of A/D312) PDK000020K - Hose kit - 1 off PCH001490K - Top hose - 1 off DNC101640K - Washer hose - 1 off TES100050K - Gearbox breather pipe - 1 off

MA300000 to WA402293 Manual models only (For vehicles not reworked as part of A/D312) PDK000020K - Hose kit - 1 off PCH001490K - Top hose - 1 off DNC101640K - Washer hose - 1 off

Tie wrap 100mm long locally sourced

RECALL ACTION BULLETIN No: A/D219
Land Rover 2000

IMPORTANT INFORMATION FOR PARTS MANAGERS: Due to the introduction of this recall previous hose kits STC4114K used inconjunction with A/D312 are now obsolete and must be returned to Unipart for disposal.

UK Return all current stock holding through the ‘Unidial Returns System’ using the ‘FAULTY’ category and quoting the bulletin reference in the comments field.

Europe/Rest of World Confirm quantities of STC4114K held to be scrapped on site to Mr Peter Wilsdon, Unipart Export Customer Service Manager by either ‘E’ mail or fax: ‘ E’ mail address : [email protected] Fax: +44 1865 717542 or +44 1865 384181

WARRANTY CLAIMS: UK only - Complaint code A219

Option A = MA300000 to WA410481 Automatic and Manual models = 02.20 hour

Option B = MA300000 to WA402293 Automatic models only (For vehicles not reworked as part of A/D312) = 02.70 hour

Option C = MA300000 to WA402293 Manual only (For vehicles not reworked as part of A/D312) = 02.40 hour

Europe/Rest of World - Complaint code D219 MA300000 to WA410481 Automatic and Manual models = 26.30.89/58 - 02.20 hour

MA300000 to WA402293 Automatic models only (For vehicles not reworked as part of A/D312) = 26.30.89/59 - 02.70 hour

MA300000 to WA402293 Manual only (For vehicles not reworked as part of A/D312) 26.30.89/60 - 02.40 hour

ADDITIONAL INFORMATION: A/D312 will be deleted from the Warranty campaign file to avoid confusion at a later date. It must be noted that those vehicles that formed part of the previous campaign must be reworked as part of this campaign.

RECALL ACTION BULLETIN No: A/D219
Land Rover 2000