Recall - Catalytic Converter Replacement
No: D236Ref:
Issue: 1
Date: 01/04/02
RECALL
Catalyst Inspection and Replacement
AFFECTED VEHICLE RANGE:
Range Rover (LP) SA302054 to VA350101 (Phase I)
VA350102 to VA376578 (Phase II)
SITUATION:
CATALYST DEGRADATION CAN LEAD TO NOISE AND MIL ILLUMINATION
A defect that relates to vehicle emissions exists on 1995 through 1997 model year Range Rover 4.0/4.6 vehicles imported by Land Rover North America, Inc.
Range Rover customers may experience a rattle from the underside of the vehicle. In some instances they may also experience a MIL illumination. The symptoms result from loose catalyst "bricks" within the exhaust system catalysts.
RESOLUTION:
INSPECT CATALYST PIPE MARKINGS AND REPLACE IF INDICATED
Utilizing the inspection parameters in this TIB, determine if the vehicle catalysts are within the affected build range. Both the exhaust down pipe/catalyst assemblies and the oxygen sensors must be replaced on vehicles equipped with the original design catalyst that is prone to deterioration.
NOTE:
Some vehicles within the affected VIN range may have had repairs under normal warranty provisions. These vehicles may already have correct updated replacement catalyst assemblies.
PARTS INFORMATION:
NOTE:
Parts numbers with a "K" suffix are intended for Recall repairs only. All parts in the Recall parts listing must be used for each repaired vehicle. Any retailer found to have abused this stipulation will be subject to audit. Parts orders will be monitored to ensure appropriate parts usage.
WCD000860K Down pipe assembly Qty 1
FX110047L Flange nut Qty10
ESR3260 Gasket Qty 2
NV108041L Nut Qty2
ANR3643 Set screw Qty 2
ERR1834K Oxygen sensor Qty 4 Up to VA350101
AMR6244K Oxygen sensor Qty 4 VA350102 - VA376578
LRN0002LABEL Recall Label Qty 1 Note order quantity 1=100 labels
WARRANTY CLAIMS:
D236 (Option 1) Time 0.20 hrs.
Inspect down pipe/catalyst assembly
D236 (Option 2) Time 1.50 hrs
Inspect down pipe/catalyst and replace along with oxygen sensors
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
INSPECT CATALYST FOR DATE CODE
1. Raise the vehicle on a lift.
WARNING:
Catalysts can be extremely hot even after a short period of operation. Verify that the catalyst is cool before starting work on the system.
NOTE:
The date code is stamped directly on the side of the catalytic converter or stamped on a plate attached to the converter.
2. Determine if the catalyst requires replacement as follows:
^ Verify the part number of the catalytic converter is either ESR4219 or ESR413O
^ Refer to Figure 1 and determine the date code on BOTH catalysts.
NOTE:
Catalyst assemblies may have been replaced as a warranty repair so the vehicle VIN may not be an accurate guide for replacement requirements.
It is also possible for one catalyst in a system to be within the date range of this Recall while the other is outside the range.
If either catalyst has a date code before "30-98" (Week 30 in 1998) the down pipe/catalyst assembly must be replaced.
3. If EITHER catalyst date code is ON or BEFORE the date code of "29-98," go to "Replace Pipe/Catalyst Assembly and Oxygen Sensors" and perform the Recall repair.
4. If BOTH catalyst date codes are ON or AFTER the cut-off date code "30-98," claim D236 (Option 1) for the inspection and go to "Install Campaign Label" to place label on vehicle. No repair action is required.
REPLACE PIPE/CATALYST ASSEMBLY AND OXYGEN SENSORS
1. Refer to Section 30.10.09 "Exhaust Front Pipe" in the Range Rover Workshop Manual (RAVE).
2. Remove the down pipe/catalyst following the WSM procedure. (Figure 2)
3. Install the replacement down pipe/catalyst assembly.
CAUTION:
If a new sensor has been dropped internal damage may result. A dropped or damaged sensor MUST NOT BE USED.
4. Inspect replacement oxygen sensors and ensure that each is free from external damage.
5. Verify that correct oxygen sensor for VIN range has been selected for installation.
NOTE:
The new sensors are pre-treated with anti-seize compound. No further application of anti-seize material is required.
6. Install new sensors finger tight.
CAUTION:
Use of "crow foot" adapter (LRT-12-047) enables the sensors to be tightened correctly. APPLYING PROPER TORQUE TO THE SENSOR IS CRITICAL.
^ Experience has shown that if the sensor is overtorqued, there is a possibility that the body of the sensor element can distort, causing a cracked sensor element.
^ Use of the proper tool and the proper torque specification is essential for proper installation.
7. Use adapter LRT-12-047 and tighten each new sensor to 20 Nm (15 lbf.ft.).
8. Route sensor cables to avoid any contact with exhaust or catalyst components.
9. Connect harness and sensor connectors until a positive "CLICK" is heard.
10. Verify each connector latches securely.
INSTALL CAMPAIGN LABEL
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:
a) Place the label on a hard surface.
b) Use a ballpoint pen to neatly write/scribe in the bare aluminum areas of the label the following information:
^ Service Action code "D236"
^ Your retailer code
^ The date of repair
2. Clean all grease and dirt from the radiator support member.
3. Peel the completed campaign label from the backing paper and position it on the cleaned area of the support member.
4. Roll the label with the special roller tool to ensure that the adhesive makes continuous contact with the support member surface.