Recall - Underhood Hose/Clamp Replacement: Overview
No: D221-D222Ref: Replaces D321-D323
*Issue 2
Date 12/22/00*
RECALL
Under-hood Tubing and Hose Replacement
* indicates updated information
AFFECTED VEHICLE RANGE:
RANGE ROVER (LP) SA302295 to XA410481*
* See individual Campaign Codes
SITUATION:
DURABILITY IMPROVEMENTS TO UNDER-HOOD COMPONENTS
NOTE:
This Recall process supersedes and replaces Recall Campaigns D321-D323. This Recall procedure is complicated because of the variety of repairs involved and the wide range of vehicles affected. When commencing a repair refer to the chart below under "Resolution" and follow each of the repair procedures specified for the VIN of the vehicle.
Land Rover has determined that certain hose and tubing components used in the manufacture and repair of Range Rover vehicles prior to VIN WA410481 could fail in service. The resulting loss of fluid from these components represents a risk of fire under certain extreme circumstances. Improvements made in current production will be installed on recalled vehicles.
RESOLUTION:
REPLACE SPECIFIED COMPONENTS IN UNDER-HOOD AREA
Under these Recall actions the new-specification components will be installed on early production vehicles and on vehicles previously recalled for coolant hose replacement. The repairs will improve the reliability and safety of these vehicles. Because of the range of vehicles involved, two Recall repair combinations are possible.
NOTE:
Always verify that the vehicle is within the specified Recall VIN range and that the Recall procedures have not been previously performed.
In order to determine if a specific vehicle is affected by this campaign, it will be necessary to utilize the Vehicle Warranty/Recall Search function of the DCS - Land Rover Link On-line. Based on the response of the system, either proceed with the corrective action or take no further action.
CARE POINTS FOR RECALL D221-D222
NOTE:
To ensure proper execution of this campaign the following care points are provided to assist the technician.
USE OF CORRECT MINI-CLAMPS
^ Ensure that only factory-approved mini-clamps listed in the parts catalog are in all locations. (See illustration opposite.) Replace any worm-drive clamps or other unapproved mini-clamps. The only location to use worm type clamps is the reuse of original equipment worm clamps at the throttle body heater feed hose.
HOSE ORIENTATION
^ It is vital that all hoses be installed correctly on the thermostat housing. Verify that the component markings on the hoses correspond to the actual installed position of the hose.
^ Always orient hoses so that there is no contact between the hose and a hard part or moving component.
^ Always install hoses up to, but NOT OVER the depth marks on the stub tubes.
^ Align clamps according to hose markings and ensure that all clamps are square with the end of the hose. An incorrectly aligned clamp may damage the hose or apply uneven pressure to the stub pipe sealing surface.
HOSE CLAMP LOCATION AND SIZE
^ Refer to the illustration and listing on the facing page for an overview of clamp sizes and locations. It is extremely important that correct size hose clamps are used in the indicated locations. Use of incorrect clamps can lead to hose damage or improper sealing.
HEATER HOSE REMOVAL METHOD
^ To avoid potential damage to the interior heater core 0-rings, technicians should carefully cut the heater hoses from the heater core connecting tubes using a razor. Under no circumstances should the hose be forcibly twisted or pulled off. If any resistance is met, slice the hose and peal it away from the heater core tubes.
HEATER HOSE INSTALLATION METHOD
^ The fitting of the spring clamp to the intake manifold end of the hose requires a special procedure because of the lip on the stub pipe coming off of the intake manifold. To ensure that the spring clamp will fit over the stub pipe lip, the clamp must be removed from the hose BEFORE installation and placed onto the stub pipe. Then the hose is to be installed onto the stub pipe and the clamp installed onto the hose from the"front."
PRESSURE TEST REQUIREMENTS
^ The special pressure testing kit LRA-28-001 was distributed in conjunction with the Recall D321. Proper pressure testing at the correct pressures is a safe way to determine that all hoses and clamps are properly installed and tightened.
AUTOMATIC TRANSMISSION VENT PIPE ROUTING
^ Note that the Recall D321 - D323 and D221 vent pipe is routed to the LH inner fender. This is the correct location for Recall vent pipes. Vehicles built after VIN WA402293 have an alternate location because of assembly line requirements. VEHICLES SUBJECT TO RECALL D221 SHOULD USE ONLY THE ROUTING DESCRIBED IN THIS TIB. Verify that the vent pipe end has been modified to conform to the configuration specified in this bulletin and in Recall TIB D352.
PARTS INFORMATION:
WARNING:
Replacement Hose PCH001490K MUST be substituted for the upper radiator hose packaged with kit PDK000020K. Failure to do so could jeopardize the integrity of the repair.
NOTE:
Early specification spare parts held in retailer inventory may be returned using the PAF claim process. Use reason code OH and reference this TIB on the claim.
Part Number Description Qty Note
PDK000020K1T Hose set complete 1 Repair 1
^ PCH001490K Upper Hose 1 Replacement hose
^ PDK000020K Hose Kit 1
TES100050K AT Breather Pipe 1 Repair 2
(Modification may be required)
DNC101640K Washer Hose Assy. 1 Repair3
ITEMS INCLUDED IN THE MATERIAL ALLOWANCE:
^ LRNA201325 Terminal Grease Repair 4
^ RTC7601 Land Rover Coolant For top-up Repair I
^ LRN21436 Loctite 270 or
^ LRN27240 Loctite 272 Sealant Repair 3
^ NPN Dexron III ATF For top-up Repair 3
^ NPN Tie-strap 2 (3 inch) Repair 1 and 3
^ LRN0002LABEL Campaign label 1 D221 or D222
SPECIAL TOOLS
LRA-12-001 Spring Band Clamp Pliers
LR 42777 "Cobra Clip" Pliers (Distributed with the Advanced EVAPS equipment cart)
LRA-26-001 Pressure Testing Tool Set
STANDARD SHOP EQUIPMENT:
Clean coolant catch pan
WARRANTY CLAIMS:
NOTE:
The upper radiator hose from hose kit PDK000020K must be removed from the kit packaging and destroyed by cutting in half. The portion of the hose with the white markings is to be held for PSR scrapping.
Determine repairs required for applicable VIN and perform required Recall repairs.
Recall Campaign Code Options:
D221 Time 2.70 hrs.
Perform repairs 1, 2, 3, 4
Material Allowance: $10.00
D222 Time 2.20 hrs.
Perform repair 1 ONLY
Material Allowance: $3.00
Normal warranty policy and procedures apply
CAMPAIGN LABEL INSTALLATION
NOTE:
Campaign labels may have multiple campaign numbers written on them if multiple campaigns are performed at the same time.
1. When all specified repairs have been accomplished, prepare the campaign label (LRN0002LABEL) as follows:
d) Place the label on a hard surface.
e) Use a ballpoint pen to neatly write/scribe in the bare aluminum areas of the label the following information:
^ Recall Campaign code performed ("D221 or D222")
^ Your Retailer code
^ The date of repair
2. Peel the label back, apply to radiator support and roll the label with the special roller.