Part 2
COMPRESSOR REWORK PROCEDURE (RANGE ROVER)1. Install a new O-ring seal to the delivery valve-retaining plug.
2. Assemble the new spring and new delivery valve.
3. Tighten the delivery valve-retaining plug to 12.5Nm (9.2 lbf.ft).
CAUTION:
Clean the area around the valve plunger cover to prevent contamination.
4. Undo, remove and discard the two exhaust valve plunger cover securing screws to allow puller to be installed. (Figure 4)
5. Configure special tool 303-D121 to two-leg mode or alternatively, use a suitable two-leg puller. (Figure 5)
6. Install and align special tool 303-D121 and the protective button from tool 303-588 to the exhaust valve plunger cover.
7. Hand-tighten puller screw to hold plunger cover in position. (Figure 6)
8. Undo, remove and discard the remaining plunger cover securing screws. (Figure 6)
9. Clean area around each screw hole using a vacuum cleaner, to prevent debris from entering the plunger chamber.
10. Carefully back-off the puller, allowing even reduction in cover spring pressure and remove the tool.
11. Remove the cover.
12. Clean area around each screw hole using a vacuum cleaner, to prevent debris from entering the plunger chamber.
13. Remove and discard the orange O-ring seal.
14. Install the new inner spring and spacer at the center of the original outer spring. (Figure 7)
15. Install and fully seat the new orange O-ring seal. (Arrowed in Figure 7)
16. Install and align the plunger cover.
17. Install the puller and protective button.
18. Tighten tool by hand to compress springs, ensuring the cover is clamped evenly.
CAUTION: Care must be exercised to avoid cross-threading the new screws being installed. Proper installation is best performed by positioning the screw in the hole, rotating the screw counter-clockwise until a 'click' is heard and then rotating the screw clockwise by hand a minimum of two turns to engage the threads.
19. Install, but do not fully tighten, two new plunger cover securing screws into the exposed holes.
20. Undo and remove special tool 303-D121.
21. Install the two remaining new plunger cover screws and tighten to 5Nm (3.6 lbf.ft).
22. Final tighten the first two screws to 5Nm (3.6 lbf.ft).
23. Using a suitable paint marker, strike through the original part number on the compressor to identify that the unit has been reworked. 24. Install the compressor cover, spare wheel and load space floor panel.
NOTE: The ride level control module will require the latest calibration. This will be downloaded during the control module technology upgrade process (B036) detailed in this Bulletin.
NOTE: Following rework/replacement of the compressor there is no requirement to recalibrate the air suspension ride height.
25. Refer to GTR Workshop Manual section 60.50.38 and pressurize the air suspension.
*ISSUE "5" CHANGES ARE HIGHLIGHTED WITH GREY BACKGROUND AND ASTERISKS: 2006 RANGE ROVER (LM) VEHICLES ARE NOW COVERED BY THE CAMPAIGN*
B036 - Tune Updates and Enhancement Repairs
AFFECTED VEHICLE RANGE:
Land Rover LR3 (LA) VIN range specific to each Repair
Range Rover Sport (LS) VIN range specific to each Repair
*Range Rover (LM) VIN range specific to each Repair*
CONDITION SUMMARY:
Situation: Software enhancements have been introduced during the early production stages of affected vehicles. Installation of these updated software programs will enhance and stabilize the systems operation of the vehicles. Other areas of the vehicle where problems have been encountered will be enhanced also at this service opportunity.
Action: You are requested to re-configure affected vehicles using an updated WDS Software Disc 13 with patch file 5 or later. During re-configuration, it is also necessary that additional actions take place to improve customer satisfaction.
PARTS:
* STC50552................Loctite Thread Locker 242 Fluid (Shop supply)
WARRANTY:
NOTE: Repair procedures are under constant review, and therefore times are subject to change; those quoted here must be taken as guidance only. Always refer to DDW to obtain the latest repair time.
Warranty claims should be submitted quoting program code B036 together with the relevant option code from the table 7. This will result in payment of the stated time and payment for the parts included. As option codes are used, there is no requirement for you to enter SROs; these are repeated here for information only. The option that allows for the drive in/drive out allowance can only be claimed if the vehicle is brought back into the workshop for this action alone to be undertaken.
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
CONTROL MODULE TECHNOLOGY UPGRADE PROCESS
LR3 (LA) VIN 5A000259 to 6A390949
Range Rover Sport (LS) VIN 6A900109 to 6A956539
Range Rover (LM) VIN 6A192814 to 6A235003
NOTE: When updating the transmission control module software, the transmission oil temperature should be within the recommended value between -55 degree C (-67 degree F) and 80 degree C (176 degree F).
NOTE: Previous patch file versions should be installed in sequence one at a time before the latest version.
* CAUTION: Range Rover (LM) vehicles affected by this action MUST be updated only with IDS DVD104 Patch 2 as the minimum level software. WDS software may not be used.
1. Verify the correct minimum level of IDS software is installed for the vehicle being updated:*
* LR3 or Range Rover Sport IDS DVD104 - Patch File 2 or later installed
Range Rover IDS DVD 104 - Patch File 2 or later installed*
* 2. If the correct software level is installed go to step 5.*
NOTE: The software patch installation help file provides instructions for the patch file installation process and could take up to 6 minutes to download dependent on connection speed.
* 3. If the correct Patch Files has not been installed or is unknown, download the IDS software patch installation help file from GTR as follows*:
^ Logon to GTR,
^ Select 'Home' from the menu at the top of the main page.
^ From the menus on the left of the page, select 'Diagnostics' as the 'Information Type' and select the relevant model and model year.
^ From the 'All Information' results, select 'Patch Files'.
^ Click the file link 'Patch Process Help File'.
NOTE: The patch file download process could take up to 20 minutes to download dependent on connection speed.
* 4. Using the help file, follow the instructions to download and install the software patch file into IDS and ensure IDS successfully restarts.*
CAUTION: Midtronics PSC550 vehicle power supply must be connected to the vehicle battery during diagnosis/module configuration.
CAUTION: The diagnostic lead must be correctly secured and cannot be accidentally disconnected during software update.
5. Connect the Midtronics PSC550 vehicle power supply device and the diagnostic equipment to the vehicle.
* 6. Begin an IDS session.*
7. Follow the on-screen prompts and enter the vehicle VIN.
8. Wait while the vehicle configuration file (CCF) uploads.
9. Select the 'Vehicle Configuration' tab and select 'Module Programming' from the menu.
10. Select 'Configure Existing Modules'.
11. Navigate to the bottom of the existing module list and select "Reassurance Programme" to display the submenu of specific modules for this campaign.
NOTE: When "Reassurance Programme" is selected, a list of control units will appear that are to be programmed as part of this procedure. Each of these control units must be programmed in sequence to complete the requirements of Service Action B036.
* CAUTION: For current Land Rover vehicles the automatic transmission internal temperature must be less than 176 degree F (80 degree C) prior to initiating programming of the TCM. If the temperature is above the limit, IDS will display either "No Software Available For This Variant" or "Unspecified Error Has Occurred" depending on vehicle configuration. If either of these messages displays the likely cause is transmission temperature. The transmission must cool before the software update can be completed. Transmission temperature can be viewed using the IDS Datalogger.*
12. Refer to the attached "Reassurance Programme Form". Select and program the modules in the order shown on the Reassurance Program sub-menu.
13. While waiting for the software upgrade processes to complete, perform the following on LR3 vehicles:
^ Inspect E-Box sealing grommet on LR3 vehicles between VIN 5A000259 and 6A390949:
^ Open the hood and install fender protection covers.
^ Inspect the E-Box grommet for proper location and seal. (Figure 2)
^ If located correctly, no further action is required.
^ If repair is required wait until downloads are complete.
^ Perform "Upper Tailgate Support Ball Stud Rattle Repair" below on LR3 vehicles between VIN 5A000259 and 6A374836.
14. When downloads are complete, exit the WDS/IDS session and disconnect the diagnostic equipment from the vehicle.
UPPER TAILGATE SUPPORT BALL STUD RATTLE REPAIR
LR3 (LA) VIN: 5A000259 to 6A374836
WARNING:
Support the upper tailgate before removing the tailgate support.
1. Release the upper tailgate support strut from the D-pillar ball stud. (Figure 1)
2. Remove the ball stud assembly from the body.
3. Apply liquid thread-lock (STC50552/Loctite 242) to the ball spigot thread.
4. Install the ball spigot.
5. Tighten to 23Nm (17 lbf.ft).
6. Install the upper tailgate support.
ENVIRONMENTAL BOX (E-BOX) SEALING GROMMET
LR3 (LA) VIN: 5A000259 to 6A374589
CAUTION: the software download must be completed and WDS/IDS disconnected before undertaking this repair. Always observe Workshop Manual precautions when disconnecting the battery.
1. If the E-box grommet was determined to not be located correctly during the inspection above, perform the following:
^ Disconnect and remove the battery for access.
^ Install the grommet. (Figure 2)
^ Install the battery and connect battery leads.
2. Remove fender protection covers, and close the hood.
SOFTWARE UPDATE INSTRUCTIONS
CAUTION: The CCF must be uploaded from the vehicle successfully at session start to avoid problems during programming. If this is not possible, programming the vehicle SHOULD NOT CONTINUE until the CCF issue has been resolved.
NOTE: When each module is selected for programming from within this reassurance menu, the tester WILL NOT read the vehicle CCF just prior to the module software selection and download as it now does for all other programming procedures.
1. Verify that the CCF data was successfully read from the vehicle.
2. Select the Control Modules to be programmed in sequence:
^ Engine Control Module: (Petrol PCM)
^ Heating and Ventilation Control Module: (HVAC)
^ Instrument Pack: (IPK)
^ Ride Level Control Module: (RLM)
^ Transfer Case Control Module: (TCCM)
^ Transmission Control Module: (TCM)
3. When each module has completed its program cycle, record the programming in the appropriate box on the record keeping page.
NOTE: After successfully programming the Ride Level Control Module, the Reassurance Program sequence DOES NOT request a ride height calibration. This unique behavior is not an error but a time saving feature. The software is functioning correctly for this specific programming condition.
4. Return to the "Reassurance Program" menu and select the next listed control unit in turn and complete the programming of each one in sequence.
5. When the download of software to each module is completed, follow the WDS routine process to clear all fault codes.
NOTE: Two module programming messages may appear during the tune download processes associated with the Reassurance Programme. WDS may fail to complete the task and displays generic error messages: "application failed" and "software not available".
6. If the failure messages "application failed" or "software not available" appear, use the IDS debug monitor trace. (Refer to Trace Procedure attachment)
7. Send the completed monitor trace to the Land Rover Technical HelpLine and contact the HelpLine for assistance.
HOW TO RUN "MONITOR TRACE"
Introduction:
The IDS Monitor Trace application is a powerful data collection tool that enables users to capture details of a failed IDS process. In many cases collecting this data before contacting JLRNA for assistance with a problem vehicle or a possible IDS software error can help expedite a solution by having this detailed info ready to send to JLRNA for review.
The monitor trace output file collects some of the following vehicle/environmental details along with actual IDS software debug info. (Content varies from procedure to procedure.)
^ Vehicle battery (system) voltage.
^ Details of failed or successful communication between IDS and the vehicle.
^ Results of CCF evaluation and vehicle control module software selection procedures.
^ User inputs.
^ Control module status and VIN numbers.
Having an IDS monitor trace file ready when contacting JLRNA can reduce the time technicians must spend on the phone with helpline staff in situations that are not easily resolved. In some cases the problem can only be resolved with the data available from an IDS monitor trace. This is especially true if IDS reports errors during software download/reprogramming of a vehicle's control modules.
Bear in mind that when JLRNA must troubleshoot a failed IDS procedure, having this monitor information the only way to identify a root cause effectively. This would be equivalent to how technicians use Diagnostic Trouble Codes to troubleshoot a "Check Engine Light" or other MIL.
When collecting a monitor trace, it's important to have the monitor application active during the procedure/failure you are attempting to collect data for. It is also important to start the trace before starting the current session.
Here is an outline of how this should be done in the service bay.
IMPORTANT:
Always have the Midtronics PSC-550 power supply connected to the vehicle battery when using IDS for diagnosis or vehicle programming.
1. IDS reports a failure, or the technician gets unexpected results from an attempted procedure using IDS.
2. Exit the current diagnostic session, and return to the VIN entry screen.
3. Start the IDS Monitor Trace application.
4. Allow the Monitor to continue running as the new diagnostic session is started.
5. Enter the VIN and continue into the diagnostic session as normal. (Do not read DTC's unless this process is the one that you are trying to collect a trace for.)
6. After IDS displays the Content Model, proceed directly to the procedure/task that originally failed, or caused the original concern.
7. Make another attempt to perform the procedure.
8. If the procedure was again unsuccessful, return to the IDS Monitor Trace application to save the trace results (details begin on next page) before doing additional work with the monitor running.
9. If the procedure was now successful, the IDS Trace Monitor can be closed without saving the trace details.
10. Currently, the only way to transfer IDS Monitor Trace files to JLRNA is via E-mail, be prepared to forward this file when requested.
How to Set - Up & use the IDS Monitor Trace