Repair 1
REPAIR 1: Coolant Hose Replacement:REMOVAL OF OLD HOSES - REPAIR 1
NOTE:
The care points and information presented below MUST be observed when performing this repair. Refer to the Workshop Manual Section 26 for additional guidance regarding removal and replacement of all hoses.
1. Verify that kit PDK000020K upper radiator hose (Position 8, Figure 2) has been replaced with new hose PCH001490K identified by green markings.
2. Remove radiator drain plug and drain coolant into a clean container. Retain coolant for refill.
3. Refer to WSM and remove serpentine belt and fan assembly to provide access.
4. Remove and discard all the following hoses along with the in-service hose clamps: (Figure 2)
^ Heater inlet hose (1)
^ Heater return hose (2)
^ Bypass hoses (4)
^ Top hose (8)
^ Throttle body heater return tube (9)
^ Radiator bleed line (10)
5. Remove thermostat and attached hoses:
^ Heater return hose to thermostat (3)
^ Radiator to thermostat hose (5)
^ Bypass hoses (6)
^ Bottom hose (7)
6. Set aside thermostat with hoses still attached.
7. Remove Throttle body heater feed hose (Figure 2 Position 11) and retain worm drive clamps for future use.
INSTALLATION OF NEW HOSES - REPAIR 1
NOTE:
To improve ease of installation, spring-band style hose clamps are pre-installed on the hoses. Use the Land Rover hose clamp pliers tool (LRA12001) to spread the hose clamps and to avoid damage to the plated clamp surface.
CAUTION:
Careful hose and clamp installation is critical to a good repair:
^ Attention must be paid to hose alignment marks to ensure that hose and clamps are fitted in their correct orientation.
^ Do not apply lubricant or coolant to hoses or stub pipes.
^ All stub pipes MUST be clean and dry prior to hose installation.
1. Clean stub pipes prior to fitting new hoses.
2. Discard kit provided Cobra clamps.
3. Remove spring clamp from intake manifold end of heater hose (Figure 2 Position 1) and position onto intake manifold stub pipe.
*4. Slide saved worm drive clamps onto new Throttle body heater feed hose. (Figure 2 Position 11)*
5. Remove hoses from the thermostat housing one at a time and replace each hose with new hose from the kit ensuring correct orientation of each hose.
6. Install all new hoses 1 through 9 in Figure 2 starting with the thermostat housing and hoses attached to it in Step 5.
CAUTION:
Stub pipes are marked for depth and hoses are marked for clamp position and labeled to indicated hose orientation. Depth marks and orientation marks can be used as a general guide for hose position. However, the primary indicator of correct hose positioning must be that there is no hard contact with moving or static parts.
7. Verify that all hoses are correctly aligned and installed to correct depth. (Figure 3)
8. Install spring clamps using special tool LRA-12-001.
9. Tighten worm drive clamps on throttle body heater feed hose to 3Nm (27 lbf.ft.). (Figure 2 Position 11)
10. Install new radiator expansion tank bleed line (Figure 2 position 10) as follows:
^ Fit cable retention clip DYC101410 to "L" metal bracket PYH100390.
^ Install the bracket and clip assembly to the front fastener of the fuse box, using the original bolt. (Figure 4 Position C)
^ Remove the battery box cover for access.
^ Drill a 6.3 mm (0.250 in.) hole in the front battery clamp bracket 48 mm (1.900 in.) from the front fastener location.
^ Touch-up exposed metal to prevent corrosion.
^ Insert new clip PYC102830 into the drilled hole from the underside of the battery clamp bracket. (Figure 4 Position A)
^ Install the new radiator-to-expansion-tank bleed line following the routing as shown in Figure 4.
^ Position mini-clamps at radiator and expansion tank. (Figure 4 Positions D & E)
CAUTION:
Incorrect orientation or over-tightening the tie strap in the next step could crimp or restrict flow in the bleed line.
^ Loosely install a tie wrap around the bleed line and through the rear fastening hole of the fuse box to locate the bleed line. (Figure 4 Position B)
^ Verify orientation of the tie-wrap is toward the front of the vehicle.
^ Check the routing of the bleed line to ensure there are no kinks and that there is no contact with the inner fender or radiator mounting points.
11. Install the battery box cover.
12. Verify that all hoses are positioned clear of moving parts.
13. Verify that there is no hard contact between a hose and a static part that could induce wear.
14. Install fan assembly and serpentine belt.
15. Install the radiator coolant drain plug.
COOLANT SYSTEM FILL AND TEST - REPAIR 1
WARNING:
Land Rover coolant/water mix MUST always be a 50/50 mix. Mixtures containing more than 50% coolant increase the risk of combustion.
CAUTION:
Extended Life Coolant is not approved in vehicles covered by this Recall and may NOT be used when conducting these repairs. Additives should NEVER be used with coolant.
1. Remove expansion tank cap.
2. Fill the system using the coolant previously drained.
3. Top up the system with Land Rover coolant (RTC7601) to the correct level using Workshop Manual procedure 26.10.01 without disturbing any hose clamps or connections.
NOTE:
Pressure caps should release pressure at 1.4 bar (20 psi). The cap release pressure may vary by plus or minus 0.2 bar (3 psi). Cap design may cause the first test to be above the range. Retest any cap that fails the first test. Retests should be consistently correct.
4. Using pressure-testing kit LRA-26-001 perform pressure expansion tank cap test at 1.4 bar (20 psi).
5. Replace pressure cap (ESR148O) if it fails two pressure tests in a row.
WARNING:
Spilled fluids can be a hazard. Ensure that any fluids spilled during repairs in the under-hood area are cleaned up.
6. Use pressure-testing kit LRA-26-001 and pressurize cooling system to 2 bar (29 psi).
7. Wait 3 to 5 minutes and inspect for leaks.
8. Correct any leaks observed, verify coolant level and install expansion tank cap.