Recall - Engine Idler Pulley Replacement
No: D216Ref:
*Issue: 3*
Date: 12/08/00
RECALL
Idler Pulley Replacement
* indicates updated information.
AFFECTED VEHICLE RANGE:
DISCOVERY Series II (LT) XA200253 to YA277051
XA900000 to XA907211
*All Discovery Series II vehicles in VIN range
RANGE ROVER (LP) XA400939 to YA443345
Bosch engine management system equipped ONLY*
SITUATION:
IDLER PULLEY FAILURE
*The left-hand engine idler pulley is subjected to high serpentine belt loads. The original specification engine idler pulley used may fracture and ultimately fail in use. Should failure occur, the accessory drive-belt will be damaged resulting in the loss of accessory drive and affecting power steering, alternator, engine cooling, air conditioning systems and ACE pump, if so equipped.*
RESOLUTION:
REPLACE IDLER PULLEY
*A new idler pulley constructed of steel has been introduced into production. The steel idler pulley assembly is to be installed on all vehicles within the affected VIN range as part of this Recall action to ensure the long-term integrity of the serpentine belt pulley/idler system.*
All affected vehicles currently held in Retailer inventory as new or used vehicles must be repaired prior to sale.
PARTS INFORMATION:
LRN0002LABEL Campaign Label Qty 1 (Order quantity 1=100)
PQR101150K Steel heavy duty idler pulley Qty 1
*CAUTION:
Some Range Rover vehicles may have been fitted with a longer specification belt (PQS101630) during repairs. The PQS101630 is intended ONLY for use with an 80 mm diameter RH pulley (identified by a black dust shield). Refer to TIB 12/04/99/NAS for additional information. Ensure that the correct belt is installed on the vehicle under repair.*
NOTE:
Belt replacement is not part of this Service Action. Only damaged belts may be replaced. A regular (type "R") warranty claim for the part only should be submitted in such cases. Reference "D216" in comments section and describe belt damage.
ERR6896 Polyvee Belt (Discovery II with ACE) Qty 1
*ERR6898 Polyvee Belt (Discovery II without ACE) Qty 1*
*PQS101480 Polyvee Belt Range Rover Qty 1 With 70 mm RH pulley*
*PQS101630 Polyvee Belt Range Rover Qty 1 With 80 mm RH pulley*
TOOLS
LRT-12-093 Viscous coupler retaining tool
LRT-12-094 Viscous coupler wrench
15 mm box end wrench
WARRANTY CLAIMS:
*D216 Discovery Series II Time 0.50 hrs
Replace LH Engine Idler Pulley
Range Rover Time 0.40 hrs
Replace LH Engine Idler Pulley*
NOTE:
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.
Normal warranty policy and procedures apply
REPAIR PROCEDURE
PULLEY REPLACEMENT
1. Refer to Workshop Manual repair sections 26.25.19 and 86.10.03 for 1999 and 2000 model vehicles and disassemble the idler pulley and the belt system as follows:
^ Remove the cooling fan assembly using special tools LRT12-093 and LRT-12-094.
^ Remove the bolts securing the drive belt cover and remove the cover.
^ Release the drive belt tensioner.
^ Remove the belt.
^ Remove the idler pulley identified by the arrow in the illustration. (Figures 1, 2 and 3)
2. Clean all pulley grooves in all locations.
3. Inspect and verify that there is no damage to any groove in the belt pulley system.
4. Install new idler pulley (PQR101150K).
5. Torque the idler pulley retaining bolt to 50 Nm (37 lbf.ft.).
CAUTION:
Casting flash on the idler mounting base can cause dimensional variances which may result in interference with the new steel idler pulley. Inspection and verification of proper clearance must be made to ensure correct installation.
6. Rotate pulley and verify proper clearance of 0.5mm (0.020 inches) from engine mounting bracket casting.
7. Relieve excess casting material if required. (Figure 4)
8. Inspect the belt for damage before installation.
9. Install the belt following the WSM procedure and tighten the tension pulley to 45Nm (33 lbf.ft.).
10. Refer to WSM section 26.25.19 and install the cooling fan assembly.
11. Install the drive belt cover.
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:
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:
^ Recall Campaign code performed ("D216")
^ Your Retailer code
^ The date of repair
2. Peel the label back, apply to radiator support and roll the label with the special roller.