Body - Squeak And Rattle Kit Availability
LTB00389NAS2
22 MAR 2012
ISSUE '2' CHANGES ARE HIGHLIGHTED IN GRAY
SECTION: 501
Squeaks & Rattles Kit Availability
AFFECTED VEHICLE:
CONDITION SUMMARY:
Situation:
During a vehicle's lifetime, some vehicle components may have been removed for various reasons, and thus may have disturbed various other
components fitted to the interior / exterior of the vehicle. Differences also occur within the interior or exterior temperature of the vehicle. All of
these symptoms may lead to various squeaks and rattles issues.
See the list below for the description of the different types of plastics the Squeaks & Rattles Kit is designed for.
^ ABS: Acrylonitrile Butadiene Styrene
^ ABS-PC: Acrylonitrile Butadiene Styrene - PolyCarbonate
^ TPO: Thermoplastic PolyOlefin
NOTE:
See below for a list of the products in the Squeaks & Rattles Kit.
A squeaks and rattles kit has been developed with Newgate Simms. This kit will be automatically shipped to each retailer, enabling retailers to use
the same professional fluids and tapes that are currently used in
vehicle manufacturing to solve any squeaks and rattles issues. Refer to Service Bulletin STE12-02 for details of how to order additional kits or
replenish the items in the kit when necessary.
2
3
4
SQUEAKS & RATTLES KIT CONTENTS INFORMATION:
Disclaimer
Land Rover Range Rover Technical Service Bulletin # TECLTB003292 Date: 110614
A/C, Electrical - Rear Glass Defogger Element Repair
No: LTB00329 (Issue 2)
14 JUNE 2011
ISSUE "2" CHANGES ARE HIGHLIGHTED IN GRAY
SECTION: 501
HEATED REAR SCREEN HEATER ELEMENT REPAIR
5
AFFECTED VEHICLES
CONDITION SUMMARY:
Situation
Action
PARTS
TOOLS
6
WARRANTY
REPAIR PROCEDURE
7
8
REPAIR HEATER REAR SCREEN HEATER ELEMENTS
Land Rover Range Rover Technical Service Bulletin # G96-005 Date: 960624
Technical Literature Corrections/Suggestions
Bulletin:
G96-005
Section:
General
Date:
6/24/96
Model:
All
Applicable to:
USA/CDA
Subject
TECHNICAL LITERATURE CORRECTIONS/SUGGESTIONS
In order to improve the usefulness and accuracy of North American technical literature, LRNA has established a direct link with Land Rover in the
U.K. for corrections to and suggestions for British-sourced technical materials. Land Rover will respond to each request submitted from this market.
In addition, every suggestion submitted for LRNA-produced technical/warranty literature/ materials will be logged and reviewed.
The attached form is to be used to submit any correction or comment you might have about technical (including warranty) literature. This form will
be included with North American sourced publications. Additional forms can be obtained by calling (301) 731-8518.
Your input is vital to the success of this program, because as a retail user, you are most familiar with any shortfalls in the existing literature. Thanks
for your participation.
Land Rover Range Rover Technical Service Bulletin # TE700104 Date: 040326
Brakes - Shudder/Judder Felt in Steering Wheel
No: 70/01/04/NAS
Ref:
Issue: 1
9
Date: 26 March 2004
Steering Wheel Judder or Vibration
Under Braking
AFFECTED VEHICLE RANGE:
New Range Rover (LM)
Up to 4A 159171
SITUATION:
PULSATION FELT DURING BRAKING
The customer may complain that a vibration or judder is felt in the steering wheel during braking.
The front brake discs may have worn unevenly, resulting in thickness variations on the discs.
RESOLUTION:
INSTALL NEW BRAKE ROTORS AND PADS
Should a customer express concern of the steering wheel vibration described above, install new front brake discs in combination with new
specification front brake pads as outlined in this bulletin.
PARTS INFORMATION:
SFC500050 Front brake pads Qty 1
SDB000201 Front brake discs Qty 2
AS400 WARRANTY CLAIMS (CANADA ONLY)
70.12.31 Time 1.00 hrs
Install front brake discs and pads
FAULT CODE: L
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply. Material allowance is included in labor operation.
REPAIR PROCEDURE
REPLACE FRONT PADS AND ROTORS
1. Refer to RAVE section 70.40.02 and remove the front brake pads.
2. Remove and replace each front brake rotor as follows:
^ Remove the two bolts securing the left-hand brake caliper to the hub.
CAUTION:
The caliper MUST NEVER hang on the brake hose during the repair.
^ Release the caliper from the hub and tie aside
avoiding strain on the brake hose.
10
^ Remove the Allen screw securing the brake disc to the drive flange and remove the disc. (Figure 1)
^ Ensure the mating surfaces of the new disc and of the drive flange are clean.
^ Install a new disc (SDB000201) to the flange. Install Allen screw and tighten to 16 Nm (12 lbf.ft).
^ Position the caliper to the hub, install bolts and tighten to 110 Nm (81 lbf.ft).
3. Perform step 2 on the alternate side brake disc.
4. Refer to RAVE section 70.40.02 and install the new front brake pads (SFC500050).Land Rover Range Rover Technical Service Bulletin # TEC800101 Date:
010105
A/C, Engine Cooling System - Heater Hose Coolant Leaks
No: 80/01/01/NAS
Ref:
Issue: 1
Date: 1/05/01
Replace Heater Pipe-to-Core Seal
AFFECTED VEHICLE RANGE:
Range Rover 4.0/4.6 (LP) ALL
SITUATION:
LEAKAGE FROM HEATER PIPE-TO-CORE FITTING REQUIRES SEAL REPLACEMENT
Stress or other influences can cause seepage of coolant from the heater core seals. A simplified work process reduces the required time for the repair.
RESOLUTION:
USE REVISED PROCEDURE TO REPLACE HEATER CORE SEALS
A new method, derived from field experience in the North American market has been written into the approved Workshop processes. Follow the
steps outlined in this TIB whenever Range Rover heater core seals are to be replaced.
PARTS INFORMATION:
STC3262 Core 0-ring Seal Qty 2
WARRANTY CLAIMS:
NOTE:
This new operation number and time should be used whenever replacing just the 0-rings on a heater core experiencing 0-ring seepage.
80.20.25 Time 3.00 hrs.
Replace heater core 0-rings
FAULT CODE: M
Normal warranty policy and procedures apply
11
REPAIR PROCEDURE
REMOVAL
1. Refer to WSM 80.20.25
2. Remove battery cover and disconnect ground.
WARNING:
Removal of the filler cap from the coolant expansion tank while the system is hot could release scalding coolant or steam.
3. Remove coolant expansion tank cap.
4. Use hose clamp tools and clamp off heater hoses.
5. Remove heater and air conditioning controls.
6. Remove glove box.
7. Protect carpet from coolant spillage.
8. Use a flashlight to locate the head of the heater pipe clamp retaining screw.
CAUTION:
Retaining screw must not be removed from its location.
9. Use a long thin screwdriver and rotate screw to release pipe clamp.
10. Release pipes from heater core.
11. Remove and discard 0-rings.
INSTALLATION
1. Clean heater pipes and mating face on heater core.
12
2. Install new 0-rings onto pipes. (Figure 1)
3. Install pipes into heater core openings.
4. Position pipe clamp, using clamp guides to ensure correct alignment, and tighten the screw.
5. Remove hose clamp tools.
6. Top up cooling system.
7. Pressurize cooling system and check for leaks.
8. Replace glove box.
9. Replace heater and air conditioning controls.
10. Connect battery ground lead and install battery cover.
Land Rover Range Rover Technical Service Bulletin # TEC120100 Date: 000929
Engine - Valve Guide Cleaning
No: 12/01/00/NAS
Ref:
Issue: 1
Date: 09/29/00
13
Use of Land Rover Tools for Valve Guide Cleaning
AFFECTED VEHICLE RANGE:
Range Rover (LH & LP) All
Discovery (LJ & LT) All
Defender (LD) All
SITUATION:
CYLINDER HEAD OVERHAUL DIFFICULTIES
Cylinder head overhauls, particularly in cases of exhaust valve sticking, have previously been carried out using a single Valve Guide Cleaner
(LRA-12-003) as directed in the Land Rover V8 Engine Overhaul Manual. The use of the single cleaner has in some cases been difficult. Also repeat
valve stick failures due to further carbon build-up over time have occurred.
RESOLUTION:
STEPPED SET OF VALVE GUIDE CLEANER TOOLS
Land Rover has now introduced a stepped set of three cleaners, designed to increase the exhaust valve guide internal diameter by 10 microns
(0.0004"), and to ensure that all carbon and valve guide material can be removed as easily as possible.
The process set out in this TIB should always be used where exhaust valve stick is suspected or confirmed to have occurred. This process replaces
the exhaust valve guide process described in the Engine Overhaul Manual and should be used for all valve replacement and cylinder head overhaul
processes.
TOOL INFORMATION
WARRANTY CLAIMS
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
NOTE:
Vehicles with Bosch Engine Management systems require Prior Authorization before performing valve stick repairs.
1. Confirm exhaust valve stick occurrence by identifying appropriate misfire codes via TestBook.
2. Remove rocker shaft and valve springs.
3. Verify sticking exhaust valve diagnosis before head removal by manually moving the valves.
4. Refer to the Land Rover Engine Overhaul Manual on latest RAVE CD and remove cylinder heads.
5. Remove inlet and exhaust valves.
CAUTION:
The Valve Guide Cleaners are hand tools only, and MUST NOT be used with any power tool. Use of power tools will lead to premature
wear of the tool and damage to the valve guide.
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CAUTION:
The process outlined in Steps 6 through 8 should be used to clean exhaust valve guides only. Perform intake valve guide cleaning as
described in Step 9.
NOTE:
Cleaner LRA-12-008 is designed to match the nominal size of the valve guide. It is possible that a small amount of valve guide material
will be removed from valve guides that are manufactured at the lower end of the tolerance band.
6. Insert cleaner LRA-12-008 by hand into each exhaust valve guide from the combustion face side of the cylinder head using T-handle
LRA-12-005.
^ Turn cleaner carefully clockwise to clear out all carbon deposits from the guide.
^ Continue turning until the cleaner can be withdrawn from the other end of the guide to prevent burrs being formed on the inner diameter of
the guide.
^ Clear out all loose material from the valve guides using the valve guide brush LRA-12-004.
^ Ensure that no carbon deposits or valve guide material remain inside the guides.
NOTE:
Cleaner LRA-12-003 is designed to enlarge the valve guide to the top of the tolerance band. A small amount of valve guide material is
likely to be removed during this process.
7. Insert cleaner LRA-12-003 by hand from the combustion face side of the cylinder head using T-handle LRA-12-005.
^ Turn cleaner carefully clockwise.
^ Continue turning until the cleaner can be withdrawn from the other end of the guide.
^ Clear out all loose material from the valve guides using the valve guide brush LRA-12-004.
^ Ensure that no deposits or valve guide material remain inside the guides.
NOTE:
Cleaner LRA-12-007 is designed to enlarge the valve guide to 10 microns (0.0004") oversize. A small amount of valve guide material will
be removed during this process.
8. Insert cleaner LRA-12-007 by hand from the combustion face side of the cylinder head using T-handle LRA-12-005.
^ Turn cleaner carefully clockwise.
^ Continue turning until the cleaner can be withdrawn from the other end of the guide.
^ Clear out all loose material from the valve guides using the valve guide brush LRA-12-004.
^ Ensure that no valve guide material remains inside the guides.
9. If carbon deposits are present in the inlet valve guides, insert cleaner LRA-12-003 by hand into each valve guide using T-handle LRA-12-005.
^ Turn cleaner carefully clockwise to clear out all carbon deposits from the guide.
^ Continue turning until the cleaner can be withdrawn from the other end of the guide.
^ Clear out all loose material from the valve guides using the valve guide brush LRA-12-004.
^ Ensure that no carbon deposits or valve guide material remain inside the guides.
10. Clean all carbon deposits from both inlet and exhaust valves, including the valve stems.
15
NOTE:
Exhaust valves should only be replaced with new items if the existing exhaust valves are not of the "carbon-break" type or the valve is
damaged. Carbon-break valves are easily identified by the reduced diameter section on the valve stem just above the valve head (Figure 1).
Valve replacement is unnecessary in most cases.
11. Lap-in all valves using a suitable valve grinding compound.
12. Remove all traces of grinding compound.
13. Assemble cylinder head using new valve stem seals on all valves.
14. Refer to the Land Rover Engine Overhaul Manual and install the cylinder heads.
15. Start the engine and check for any leaks.
16. Clear any codes stored in the engine ECU, and perform drive cycle C.
17. Check for any newly stored codes using TestBook.
18. If new codes are stored, follow appropriate diagnostic procedures.
Land Rover Range Rover Technical Service Bulletin # TEC120202 Date: 021011
Engine - Oil Leaks From Rear
No: 12/02/02/NAS
Ref: 12/01/02/NAS
Issue: 1
Date: 10/11/02
New Style "Crucifix" Seals
AFFECTED VEHICLE RANGE:
Land Rover V-8
Range Rover Classic (LH) All
Range Rover (LP) All
Discovery (LJ) All
Defender (LD) All
Discovery Series II (LT) All
SITUATION:
OIL LEAKAGE FROM REAR MAIN BEARING AREA
The customer may complain of oil leakage at the rear of the engine. Several seal areas can contribute to oil seepage in this location.
^ Leak from the rear main bearing cap side seals.
^ Leak from the rear main bearing cap sealant area.
^ Leak from the crankshaft rear oil seal.
16
In addition the rear camshaft oil galley and bore plugs can contribute to oil seepage. Refer to TIB 12/01/02/NAS for additional information.
RESOLUTION:
NEW STYLE BEARING SIDE CAP (CRUCIFIX) SEALS INTRODUCED
Where a complaint of an oil leak from the above listed area is confirmed, replace the rear main bearing cap side seals with the new rear main bearing
cap side seals now used in production. As part of the replacement of the side seals the crankshaft rear oil seal should also be replaced and the rear
cam galley and bore plugs inspected for seepage.
PARTS INFORMATION
WARRANTY CLAIMS
Normal warranty policy and procedures apply. Material allowance is included in labor operation.
REPAIR PROCEDURE
INSTALL NEW SIDE SEALS
1. Refer to the Workshop Manual section 12.53.13 and remove the torque converter drive plate or flywheel.
2. Refer to Workshop Manual section 12.60.38 and remove the sump.
3. Refer to Workshop Manual, section 86.60.01 and remove the starter motor.
4. Remove Allen side bolts from the rear main bearing cap.
5. Remove the rear main bearing cap bolts, main bearing cap and crankshaft oil seal.
6. Remove the side seals from the main bearing cap.
7. Carefully remove any residue sealant from the main bearing cap to cylinder block mating surfaces.
8. Ensure seal locations and mating surfaces in the main bearing cap and cylinder block are clean.
CAUTION:
The main bearing cap bolt holes in the cylinder block must be clean and dry.
9. Clean cap bolt holes and verify they are dry.
17
10. Fit new side seals (LUN000010) to the main bearing cap. (Arrowed in Figure 1)
CAUTION:
Ensure sealant does not enter the cylinder block bolt holes.
11. Apply a 3 mm (1/8 in) wide bead of STC50550 sealant to the main bearing cap rear mating surfaces on the cylinder block. (Arrowed in Figure
2)
12. Carefully locate main bearing cap into position.
13. Start but do not tighten side bolts.
14. Apply initial torque of 13.5 Nm (10 lbf.ft.) to the main bearing cap bolts and side bolts.
15. Apply final torque of 92 Nm (68 lbf.ft.) to the main bearing cap bolts.
16. Apply final torque of 45 Nm (33 lbf.ft.) to the main bearing cap side bolts.
17. Refer to Workshop Manual section 12.21.20 and install new crankshaft rear oil seal to crankshaft.
18. Inspect camshaft oil gallery plugs and the camshaft bore cup plug for leakage.
19. If leakage is determined, refer to Technical Information Bulletin 12/01/02/NAS and seal.
20. Install starter motor and sump.
21. Install torque converter drive plate.
Land Rover Range Rover Technical Service Bulletin # TEC820204 Date: 040618
A/C - Insufficient Cooling
No: 82/02/04/NAS
Ref:
Issue: 1
Date: June 18, 2004
AC Condenser Refrigerant Leak at Desiccant Bag Plug
AFFECTED VEHICLE RANGE:
New Range Rover (LM) Up to 4A154045
18
SITUATION:
CUSTOMER COMPLAINT OF POOR COOLING
The flux used when brazing the condenser crystallizes forming a white substance. The substance contaminates the inside of the condenser tube,
causing the plug not to seal correctly.
RESOLUTION:
INSPECT FOR LEAK AND REPLACE CONDENSER IF INDICATED
If the customer complains of poor cooling, determine if refrigerant is leaking from the condenser drier desiccant bag plug. If desiccant bag plug is
leaking, replace the condenser without attempting to repair the leak.
PARTS INFORMATION
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
REPAIR PROCEDURE
DETERMINE LEAK SOURCE AND REPLACE CONDENSER IF INDICATED
NOTE:
If refrigerant is leaking from the condenser drier desiccant bag plug, DO NOT remove the plug:
^ Attempting to remove the flux (white substance) from the condenser bore may result in damage to the condenser bore and
contamination inside the condenser.
^ Leaving the plug undisturbed will allow the supplier of the condenser to verify that flux contamination was the cause of the leak, and
also to verify that there are no other causes for the leak.
1. Verify source of leak is from the condenser drier desiccant bag plug.
2. If refrigerant is leaking from the condenser drier desiccant bag plug, refer to RAVE/GTR section 82.15.07 and replace the condenser.
Land Rover Range Rover Technical Service Bulletin # TEC820102 Date: 020222
A/C - Inconsistent Interior Temperatures
No: 82/01/02NAS
19
Ref:
Issue: 1
Date: 02/22/02
Improved HVAC Temperature Sensor
AFFECTED VEHICLE RANGE:
Range Rover (LP) Up to 1A450120
SITUATION:
INCONSISTENT IN-VEHICLE TEMPERATURES
The customer may complain of too much heat in cold conditions or being too cold in hot conditions. The in-car temperature sensor is ventilated by a
miniature fan, which draws air from inside the vehicle. The thrust bearing of the fan can wear prematurely, causing the fan to become stiff or
sluggish. The starting torque of the motor is low, permitting the motor to sit in a stalled state. When the fan fails the sensor is not ventilated and the
fascia temperature is sensed instead of the in-car temperature.
RESOLUTION:
REPLACE FAULTY IN-CAR TEMPERATURE SENSOR
NOTE:
The condition described in this TIB is NOT the "32 degree/snowflake" issue dealt with in TIB 80/01/98/NAS and Parts Bulletin PGI99-07. If a
Range Rover HVAC appears to overheat or overcool intermittently and it has the latest head unit, suspect the aspirator.
Where a customer complaint of the above is confirmed, replace the temperature sensor with a new part.
PARTS INFORMATION:
JTF000030 Temperature sensor (includes fan) Qty 1
WARRANTY CLAIMS:
82.20.93 Time 0.60 hrs.
Install replacement fan/sensor assembly
FAULT CODE: D
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
REPLACE FAN SENSOR UNIT
1. Use the smoke from an extinguished match or similar source to determine that the sensor motor has stalled.
2. Refer to Workshop Manual, Air Conditioning, section 82.20.93 and perform the fan/sensor replacement repair.
Land Rover Range Rover Technical Service Bulletin # RB166 Date: 050308
Recall - Right Side Exhaust Manifold Cracking
No: RB166
20
FGN
Ref:
Issue: 1
Date: March 08, 2005
RECALL ACTION
Right Side Exhaust Manifold Cracking
AFFECTED VEHICLE RANGE
Range Rover (LP) YA441200 to 1A457215
SITUATION:
RIGHT SIDE EXHAUST MANIFOLD CAN SPLIT
A possible defect which relates to motor vehicle emissions may exist in some 2000 through 2001 model year Range Rover vehicles imported by
Land Rover North America, Inc.
Land Rover has decided to recall all Range Rover vehicles, within the above VIN range. There is a possibility of the right side exhaust manifold
collector pipe splitting at the collector joint. A split can allow exhaust gas to discharge in the under-hood area.
RESOLUTION:
INSPECT MANIFOLD FOR MAGNETISM AND REPLACE IF INDICATED
Check the installed RH manifold for magnetic material according to the procedure in this bulletin. It is critical that the procedure is followed
precisely. If magnetic properties are detected, the manifold is not manufactured to the correct metallurgical specification and must be replaced.
TOOLS
PARTS INFORMATION
DDW WARRANTY CLAIMS:
21
Warranty claims should be submitted quoting program code B166 together with the relevant option code from Table 2. This will result in payment of
the stated time and, where applicable, parts/miscellaneous expense codes. As option codes are used, there is no requirement for you to enter parts or
labor, these are repeated here for information only.
Drive in/drive out can only be claimed if the vehicle is brought back into the workshop for this action alone to be undertaken.
REPAIR PROCEDURE
INSPECT MANIFOLD AND REPLACE IF INDICATED
1. Before performing any B166 Recall activity obtain the correct tool to inspect the manifold for magnetism.
2. Raise the vehicle.
NOTE:
Due to the proximity of ferrite (magnetic) components such as the collector flange and heat shield, care must be taken to accurately define
the source of the magnetism.
22
3. Using a shielded magnetic implement, such as a retrieval tool, determine if the right side manifold collector pipe exhibits magnetic properties.
(Figures 1 and 2)
4. If the pipe is non-magnetic at the inspection location, lower the vehicle and claim Option "A" or Option "K"
5. If the manifold exhibits strong magnetic properties, perform the following manifold replacement steps:
^ Inspect the replacement component prior to installation to ensure that the replacement part LKC102470K does not exhibit strong magnetic
properties.
NOTE:
GTR lookup sequence is as follows: GTR Home > NAS > Service Information/LP Range Rover/2001 > Workshop Manuals > Range
Rover > Bookmark "30 - Manifold and Exhaust System' > bookmark "EXHAUST MANIFOLD GASKETS - V8 - 99MY"
^ Refer to GTR section 30.15.16 and install a new right hand exhaust manifold.
^ Lower the vehicle.
^ Claim Option "B" or Option "C".
INSTALL CAMPAIGN LABEL
NOTE:
Campaign labels are required for emissions - related Recalls in the United States.
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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 Campaign code "B166"
^ 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.
4. Roll the label with the special roller tool to ensure proper adhesion.
Land Rover Range Rover Technical Service Bulletin # TEC100101 Date: 010911
Wheels - Difficult to Remove
No: 10/01/01/NAS
Ref:
Issue: 1
Date: 11/09/01
Alloy Wheel-center Lubrication
AFFECTED VEHICLE RANGE:
All Land Rover products with alloy wheels
SITUATION:
ALLOY WHEELS DIFFICULT TO REMOVE
Corrosion between the wheel hub and the alloy wheel center mounting surfaces can result in a condition that makes the wheel difficult to remove for
service or tire repair. An anti-seize grease has been progressively introduced into production to help resolve this condition.
RESOLUTION:
LUBRICATE WHEEL-CENTERS
At maintenance intervals or whenever a wheel is removed for repairs, lubricate the wheel-center with a zinc-based anti-seize compound. The
anti-seize grease should be used for all models on the wheel mounting surfaces when refitting alloy road wheels.
PARTS INFORMATION
WARRANTY CLAIMS:
24
Normal warranty policy and procedures apply. Material allowance is included in applicable labor operation.
REPAIR PROCEDURE
APPLY ANTI-SEIZE COMPOUND
CAUTION:
Only the zinc based anti-seize compounds specified for use with aluminum are to be used for this maintenance procedure. Apply to the
wheel mounting surfaces only. Care must be taken to avoid contact with brake discs and pads.
1. When wheels are removed for maintenance inspections, apply a thin coat of anti-seize compound to the mating surfaces of the wheel and the
hub. (Figure 1)
Land Rover Range Rover Technical Service Bulletin # TEC760304 Date: 040227
Body - Front Door Rattles When Closed
No: 76/03/04/NAS
Ref:
Issue: 1
Date: 27 February 2004
Front Door Rattle
AFFECTED VEHICLE RANGE:
New Range Rover (LM)
Up to 3A104762
SITUATION:
FRONT DOOR RATTLES WHEN CLOSED
The customer may complain of rattles from the front door when a door is jolted by closing or other abrupt jarring movement. A number of possible
causes relating to the window mechanism and sound deadening materials may be the cause. Likely causes are:
^ Glass incorrectly fitted to glass guide channel.
^ Window regulator cable.
^ Loose window regulator.
^ Foam pad missing between the window regulator and the regulator mounting plate.
^ Clip missing or loose between the window regulator cable and the crash beam.
^ Faulty window regulator.
RESOLUTION:
INSPECT WINDOW MECHANISM FOR ROOT CAUSE AND REPAIR
25
By removing the door trim and inspecting various aspects of the window mechanism a cause for the rattle will be determined. Repair as indicated by
the inspection
PARTS INFORMATION:
A5400 WARRANTY CLAIMS: (CANADA ONLY)
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply. Material allowance is included in labor operation.
REPAIR PROCEDURE
IDENTIFY AND CORRECT DOOR RATTLE
1. Refer to RAVE Workshop Manual section 76.34.18 and remove the front door plastic sheet.
2. Lower the front door window for access to the regulator clamp Torx bolts.
3. Loosen the 2 regulator clamp Torx bolts securing the window glass (Arrowed in Figure 1).
4. Push the window glass fully rearwards into the rear glass guide channel.
5. Lightly tighten the Torx bolts.
6. Raise the window and check the glass alignment.
7. Lower the window and tighten the Torx bolts to 10 Nm (88.5 lbf.in).
26
8. Secure the regulator cables with a cable tie at the point where the regulator cables cross ("A" in Figure 2).
9. Trim the excess material from the cable tie.
10. Verify the bolt securing the regulator to the crash beam is tightened to 9 Nm (80 lbf.in) ("B" in Figure 2).
11. Verify that a foam pad has been fitted between the regulator and the regulator mounting plate (Arrowed in Figure 3).
12. If the foam pad is missing, install a new foam pad between the regulator and the regulator mounting plate.
13. Verify that the regulator is secure.
14. Check the integrity of the clip securing the regulator cable to the crash beam (Arrowed in Figure 4).
15. If the clip is loose, push the clip fully onto the crash beam.
16. If the clip is missing, secure the regulator cable to the crash beam with a cable tie. And trim the excess material from the cable tie.
17. Refer to RAVE Workshop Manual section 76.34.18 and install the front door plastic sheet.
18. Open and close the front door, listening for rattles with the window glass in the open and closed positions.
19. If rattles are still present, refer to the RAVE Workshop Manual section 76.31.45 and replace the front door regulator assembly.Technical
Service Bulletin # TEC761104 Date: 040604
Body - Slow Operation of Front Door Windows
No: 76/11/04/NAS
Ref:
Issue: 1
Date: June 04, 2004
Slow Operation Front Door Windows
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
27
SITUATION:
FRONT WINDOW SLOWS OR STOPS
The customer may complain that when operated in an upward direction the front door windows slow down, operate unevenly or do not completely
close. The lower window regulator mounting brackets may be out of position.
RESOLUTION:
INSPECT AND IF INDICATED ADJUST WINDOW COMPONENTS
Should a customer express concern regarding slow window operation, perform the timing check procedure. If the timing test indicates a problem
proceed with the adjustment procedure.
TOOLS
PARTS INFORMATION
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
REPAIR PROCEDURE
CHECK AND TIME BOTH WINDOW LIFT SPEEDS
1. Start the engine and switched off all electrical loads.
2. Lower the front door glass.
NOTE:
The use of a stop watch to accurately time the duration of the window raising operation is required to ensure that accurate information is
obtained.
3. Raise the window from fully down position to fully closed position using a stop watch to measure the time taken for the glass to fully rise.
4. Record the time observed.
5. Repeat for the timing procedure on the opposite side of the vehicle.
6. Switch off the engine.
28
7. Compare the observed times to the standards shown.
8. If the glass rises within the standard times in the table no further action is required.
9. If the glass does not rise within the standard times, follow the adjustment procedure.
ADJUSTMENT PROCEDURE - BOTH BRACKETS - ONE DOOR
1. Lower the front door glass 250 mm (10 inches). (Figure 1)
CAUTION:
When disconnecting battery ensure that all CAUTIONS and WARNINGS are observed, including wait time for NAV and SRS systems.
2. Refer to RAVE/GTR section 76.34.18 and remove the plastic protective sheet following all steps and precautions including removal of the
side airbag module.
3. Remove both lower regulator attachment bolts. (Figures 2 and 3).
NOTE:
The measuring depth gauge must be positioned flush with the door frame measuring at 90° from the frame and the bracket.
4. Determine the depth of the rear regulator mounting bracket relative to the door frame and record the measure depth. (Figure 4)
5. Determine the depth of the front regulator mounting bracket relative to the door frame and record the measure depth. (Figure 5)
29
6. Compare the regulator depth measurements to the acceptable dimensions in the table shown.
7. If adjustment is indicated, position tool LRT-76-008 over the top of the regulator mounting bracket. (Figure 6)
NOTE:
Check the depth from the door frame to bracket with the depth gauge after each adjustment movement.
8. Pry the regulator mounting bracket with the tool until the front bracket is set at 70 +/- 1.5 mm (2.756 +/- 0.059 in) and the rear bracket is set at
60 +/- 1.5 mm (2.362 +/- 0.059 in).
9. Loosen the centre regulator attachment bolt by two complete turns. (Figure 7)
10. Install and tighten the lower regulator attachment bolts to 10 Nm (7 lbf.ft).
11. Tighten the centre regulator attachment bolt to 10 Nm (7 lbf.ft).
12. Loosen two bolts securing the door glass. (Figures 8 and 9)
30
13. Position the airbag module to the door.
14. Install the used bolts removed during the water shedder disassembly and tighten to 9 Nm (6.5 lbf.ft).
15. Connect the multi-plug to the airbag module.
16. Connect the battery ground lead.
17. Close the window fully.
18. Ensure the glass has seated correctly by gently lifting the forward part of the glass to obtain a good fit into the seal.
19. Tighten the glass clamp bolts to 10 Nm (7 lbf.ft).
20. Ensure glass run seal is correctly installed.
CAUTION:
Failure to wait 2 minutes before disconnecting the battery will damage the navigation computer.
WARNING:
The SRS system requires a further ten minutes without power before work can begin.
21. Refer to RAVE/GTR battery disconnection procedures and disconnect the battery ground lead.
22. After waiting the designated 10 minute interval, disconnect the multi-plug from the airbag module.
23. Remove and discard the three bolts securing the airbag module.
24. Remove the airbag module.
25. Refer to RAVE/GTR section 76.34.18 and install the plastic sheet and airbag following all precautions and using new screws during the airbag
installation.
Land Rover Range Rover Technical Service Bulletin # TEC760601 Date: 010907
Body - Front Door Weatherstrip Wind Noise
No: 76/06/01/NAS
Ref:
Issue: 1
Date: 09/07/01
Front Door Weather Seal Wind Noise
AFFECTED VEHICLE RANGE:
Range Rover (LP) All
SITUATION:
NOISE FROM "A" POST AREA
The customer may complain of a low pitched wind noise/vibration coming from the area of the "A" pillar.
RESOLUTION:
INSTALL BUFFER TO REDUCE THE VIBRATION TENDENCY
Inserting a strip of double-sided tape in the interior of the U-shaped weather strip will provide a firm backing for the door to close against and
eliminate the tendency of the sealing lip to vibrate.
PARTS INFORMATION:
Local Source
1/2 inch double-sided tape As required
WARRANTY CLAIMS:
76.13.89/34 Time 0.30 hrs.
31
Install tape support into the door seal channel
FAULT CODE: U
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
IDENTIFY THE SOURCE OF THE NOISE AND CORRECT
1. Investigate the source of the noise and determine that it is not the upper windshield finisher. (See Service Action H201)
NOTE:
The noise generally will appear on the driver's side, but could also be present on the passenger's side door.
2. Open the door from which the noise is originating and spread the outer "A" pillar/roof seal strip to expose the door opening surfaces behind
the "U" flap. (Figure 1, A)
3. Clean the area to remove dirt.
4. Cut a strip of 1/2 inch wide double-sided tape approximately 24 inches long.
5. Remove a few inches of the adhesive protection on one side of the tape.
6. Carefully locate the exposed adhesive area against the exposed portion of the "A" pillar trim piece behind the door seal. Start at the top curve
of the seal. (Figure 2)
7. Remove the protective cover and lay the tape along the trim piece between the inner and outer seal and down the "A" pillar.
8. When one side of the tape is properly positioned remove the remaining protective strip and allow the seal "U" lip to return to its natural
position.
9. Close the door.
10. Test drive the vehicle and verify that the noise has been eliminated.
Land Rover Range Rover Technical Service Bulletin # TEC761603 Date: 030627
Interior - Various Interior Water Leaks
32
No: 76/16/03/NAS
Ref:
Issue: 1
Date: 06/27/03
Rear Load Space Water Ingress
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
SITUATION:
SEALING FAULTS PERMIT WATER ENTRY PATHS
Inconsistent manufacturing sealing processes can permit water to enter the vehicle during inclement weather from a variety of potential ingress areas.
RESOLUTION:
IDENTIFY LEAK PATHS AND SEAL
When a customer complaint of water ingress into the passenger area is confirmed, identify the likely point of ingress based on testing, water
accumulation and likely migration paths and perform the indicated operation in this TIB to resolve the problem. Some leak areas identified in this
TIB may have had sealant applied during post-production inspections.
PARTS INFORMATION:
Locally Sourced Clear RTV silicon adhesive/sealant
WARRANTY CLAIMS:
NOTE:
Select applicable repair process and then only claim against appropriate repair SRO number(s) from below.
Normal warranty policy and procedures apply. Material allowance is included in labor operation.
REPAIR PROCEDURE
REPAIR 1 - ROOF RACK FITTINGS
1. Fully lower the suspension ride height.
2. Open the six access covers in the roof channel moldings. (Figure 1)
33
3. Inspect around the roof rack location fittings for pinholes. (Arrowed in Figure 1)
4. Ensure the fittings are clean and dry.
5. Fill any holes / gaps with sealant making sure not to fill the roof rack fitting opening.
6. Wipe off any excess sealant.
7. Close access covers.
8. Return the suspension to normal ride height.
REPAIR 2 - BODY SEAMS AROUND THE TOP CORNERS OF THE UPPER TAILGATE OPENING
1. Fully lower the suspension ride height.
2. Open the tailgate.
3. Inspect the full length of the body seams at the upper tailgate opening for pinholes / gaps.
(Arrowed in Figure 2)
4. Inspect the top corner body seams for pinholes / gaps. (Arrowed in Figure 3)
5. Ensure that the seams are clean and dry.
6. Fill any holes / gaps with sealant.
7. Wipe off any excess sealant.
8. Return the suspension to normal ride height.
REPAIR 3 - BODY SEAMS - REAR
1. Refer to RAVE section 76.22.74 and remove the rear bumper assembly.
2. Inspect the following body seams, brackets and grommets for pinholes / gaps:
34
^ The rear lower panel upper and lower seams behind the rear armature (Figure 4)
^ The rearquarter panel lower seams (Arrowed in Figure 5)
^ The rear bumper mounting brackets (Arrowed in Figure 6)
^ The body seam between the tail lamp and the tailgate aperture (Arrowed in Figure 7)
^ Ensure all the grommets behind the rear bumper are fully fitted to the body.
3. Ensure the seams are clean and dry.
4. Fill any holes / gaps with sealant.
5. Wipe off any excess sealant.
CAUTION:
Care must be exercised to avoid damage to the bumper plastic components.
6. Refer to RAVE and install rear bumper assembly.
35
REPAIR 4 - TAILGATE APERTURE SEAL
1. Open the tailgate.
2. Inspect the tailgate seal for damage.
CAUTION:
Use of pliers to crimp the tailgate seal to the body could damage the seal surface if care is not taken.
3. If no damage is present, use a clean pair of pliers to carefully squeeze all around to tighten the crimp of the tailgate seal carrier. (Figure 8)
4. If the seal is damaged, replace the tailgate aperture seal.
5. Ensure there are no gaps between the tailgate seal carrier and the body.
6. Close the tailgate.
REPAIR 5 - REAR WHEEL ARCH SEAM TO THE BODY SIDE
1. Raise the air suspension to its highest ride height setting.
2. Clean the rear wheel arch seam.
NOTE:
Pay particular attention to the rearward corner.
3. Inspect the full length of the rear wheel arch seam for pinholes / gaps. (Arrowed in Figure 9)
4. Ensure the seam is clean and dry.
5. Fill any holes / gaps with sealant.
6. Ensure the sealant is pushed fully into the holes / gaps.
7. Wipe off any excess sealant.
8. Repeat for alternate side of the vehicle.
9. Return the suspension to normal ride height.
REPAIR 6 - BODY SEAMS AND GROMMETS BEHIND THE TAIL LAMPS
1. Refer to RAVE section 86.40.70 and remove both tail lamps.
36
2. Inspect body seams behind the tail lamps for pinholes.
3. Ensure the seams are clean and dry.
4. Fill any holes I gaps with sealant.
5. Wipe off any excess sealant.
6. Ensure the grommets are fitted correctly to body. (Arrowed in Figure 10)
7. Position the tail lamps and start the fastener screws.
8. Apply sealant around the fastener openings. (Arrowed in Figure 11)
9. Install the tail lamp fastener and wipe off any excess sealant.Land Rover Range Rover Technical Service Bulletin # TEC760805 Date: 050517
Body - Squeak From Upper Door Seal Area
No: 76/08/05/NAS
FGN LM50J
Ref:
Issue: 1
Date: 17 May 2005
Door Seal Lubricant for Squeak
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
SITUATION:
SQUEAK FROM UPPER DOOR SEAL AREA
A customer may report a concern of a creaking noise while driving that appears to originate from around the door aperture. The creak is caused by
the contact between the door top flip-seal and the bodywork.
RESOLUTION:
APPLY LUBRICANT TO DOOR SEAL
Should a customer complain of the described symptom, refer to the Repair Procedure detailed in this bulletin and apply the specified lubricant to
each door flip seal.
PARTS INFORMATION:
NOTE:
Sundries and Consumable Items Warranty part number ZZZ001
LRNXTR5 Carbaflo XTR5 Qty 1
DDW WARRANTY CLAIMS:
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.
NOTE:
Carbaflo XTR5 (LRNXTR5) is classed as a consumable. Each applicator will last for approximately 15 applications/vehicles. Claim only 1/15 of
the cost of LRNXTR5 against Warranty miscellaneous code ZZZ001 for each vehicle. Excessive use of the lubricant per vehicle will be subject
to warranty audit.
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
37
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
APPLY LUBRICANT TO SEAL
CAUTION:
Solvent based cleaning solutions are not to be used.
NOTE:
Surface must be clean and dry before application. Spray applicators are not approved for lubrication of this seal. Apply pen applicator to the area
of the seal that contacts the body work only along the length of flip-seal.
1. Open door.
2. Apply one coat with the Carbaflo pen applicator XTR5 to each door flip-seal along the top horizontal section. (Figure 1)
DisclaimerLand Rover Range Rover Technical Service Bulletin # TA057602 Date: 050610
Body - Carbalflo XTR5(R) Lubricant Usage
TA05 7602
June 10, 2005
Use of Carbaflo XTR5 for Range Rover (LM)
PDI and Scheduled Maintenance
Technical Information Bulletin 76/08/05/NAS introduced the use of Carbaflo XTR5, available under part number LRNXTR5, as a solution for the
squeaking noise sometimes generated by the top "flip-seal" on Range Rover doors. In addition to introducing the new lubricant, TIB 76/08/05/NAS
also more carefully defined the textured flip seal at the top of each door potentially affected by the problem.
That same flip seal should also be lubricated at each PDI and each Scheduled Maintenance Service as a preventative measure. The requirement to
apply a silicon spray lubricant on door flip seals has been replaced by the use of Carbaflo. All Maintenance and PDI Schedules relating to Range
Rover (LM) have been updated on InfoTrail to reflect the use of the newly introduced lubricant. Changes to PDI and Complimentary Scheduled
Maintenance Program reimbursement are being made to compensate for the cost of this special lubricant application.
38
To ensure that all Retailers are aware of the change to the PDI and Maintenance Schedules, and to confirm the precise seal to be lubricated please
review the illustration and the information in TIB 76/08/05/NAS found on GTR.
DisclaimerLand Rover Range Rover Technical Service Bulletin # TEC570203 Date: 030523
Steering Column - Squeaking Noise When Turning
No: 57/02/03/NAS
Ref:
Issue: 1
Date: 05/23/03
Steering Column Lubrication
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
SITUATION:
STEERING COLUMN SQUEAK
A customer may complain of a squeak from the steering column/bulkhead area when turning the steering wheel. The steering column bushing and
grommet fit condition is variable, which can result in misalignment.
RESOLUTION:
39
LUBRICATE STEERING COLUMN GROMMET
A greasing operation has been introduced in manufacturing as an interim solution to the steering column noise. Lubrication of incorrectly aligned
grommets will protect against squeaking. New installations should also be lubricated as described below.
PARTS INFORMATION:
LRN100050S Krytox Spray (Shop supply. Do not claim.)
WARRANTY CLAIMS:
57.40.89/31 Time 0.10 hrs.
Apply Krytox to steering column bushing
FAULT CODE: K
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
LUBRICATE BUSHING/GROMMET INTERFACE
1. Open the hood for access and locate the grommet and bushing between the chassis bulkhead and secondary bulkhead.
NOTE:
For illustration purposes only, the column is removed from the vehicle in Figure 1.
2. Ensure grommet and column bushing are correctly fitted and that the column bushing is correctly aligned to the grommet. (Figure 1)
3. Apply Krytox spray (LRN100050S) to the interface of the bushing and grommet.
4. Rotate steering wheel fully in both directions to ensure a uniform distribution of lubricant.
5. Verify that the squeak is no longer present.
6. Re-apply as necessary until squeak is eliminated.Land Rover Range Rover Technical Service Bulletin # TEC540303 Date: 030606
Drivetrain - Front Differential Alignment Process
No: 54/03/03/NAS
Ref:
Issue: 1
Date: 06/06/03
Front Differential Alignment Process
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
SITUATION:
ALIGNMENT FOR DIFFERENTIAL REPLACEMENT REQUIRED
The required procedure for differential alignment during replacement is not thoroughly covered in the RAVE Workshop Manual.
40
RESOLUTION:
FOLLOW DIFFERENTIAL ALIGNMENT PROCESS
For component longevity it is important that the differential and the transfer box front output flange are correctly aligned. A process has been
developed to ensure proper alignment of the transfer gearbox front output flange and the front differential.
CAUTION:
Any damage or wear to the differential drive tube splines, requires that the whole differential assembly be replaced as well as the prop shaft. The
differential assembly includes a collapsible spacer that determines the bearing preload. There is currently no acceptable procedure for renewing a
drive tube in service. If an attempt is made to change the drive tube only, rapid failure of the differential bearings will occur. Damaged or worn
splines in the drive tube will have affected the prop shaft, requiring replacement.
PARTS INFORMATION:
WARRANTY CLAIMS:
NOTE:
This SRO time is additional time that may be claimed in addition to the published SRO for Differential Replacement (54.10.01)
54.10.89/34 Time 0.20 hrs.
Check and adjust front differential alignment
FAULT CODE: A
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
DIFFERENTIAL ALIGNMENT
CAUTION:
When a new front differential is installed, the following alignment procedure MUST be carried out before fully tightening the differential bolts
and installation of the front propeller shaft.
NOTE:
This alignment procedure will be incorporated into the RAVE Workshop Manual at the next edition.
1. Remove and discard the 0 ring from the differential drive tube ("A" Figure 1).
NOTE:
All grease must be removed.
2. Thoroughly clean the differential drive tube splines ("B" in Figure 1) and the propeller shaft splines.
3. Fit the propeller shaft to the differential drive tube.
41
4. Slide the propeller shaft forwards and fit the centering flange ("A" in Figure 2) to the propeller shaft.
5. Secure the centering flange with a nut and bolt ("B" Figure 2).
6. Slide the propeller shaft rearwards until the centering flange nipple is near to its locating bushing in the transfer gearbox front output flange
(Figure 2).
7. Gently pull the propeller shaft down to its lowest position.
8. Measure and record the distance between the centering flange nipple and the center of the locating bushing in the transfer gearbox front output
flange (Figure 3).
9. Gently push the propeller shaft up to its highest position.
10. Measure and record the distance between the centering flange nipple and the center of the locating bushing in the transfer gearbox front output
flange (Figure 4).
11. If the measured distances are equal both above and below the locating bushing (Figures 3 & 4), the differential is correctly aligned to the
transfer box front output flange. Go to section Install Front Propeller Shaft".
12. If the measured distances are not equal, go to section Adjustment of Differential Alignment".
ADJUSTMENT OF DIFFERENTIAL ALIGNMENT
42
CAUTION:
Unequal alignment measurements as depicted in Figures 5 and 6 require differential alignment to the transfer box output flange.
1. Tighten the four differential bolts (Arrowed in Figure 7) sufficiently to secure the differential but allow it to rotate slightly on its axis.
NOTE:
Rotating the differential counter-clockwise will raise the drive tube. This will decrease the distance below the locating bush (shown in Figure 6).
This procedure may need to be repeated several times to achieve the desired result.
2. Lightly push or pull the propeller shaft to rotate the differential as required to achieve equal distance above and below the centering flange
spigot and the locating bush (see Figures 3 & 4).
3. Gently tighten one of the differential bolts to hold the differential in position.
4. Measure the distance above and below the locating bushing as follows:
^ Gently pull the propeller shaft down to its lowest position.
^ Measure and record the distance between the centering flange nipple and the center of the locating bushing.
^ Gently push the propeller shaft up to its highest position.
^ Measure and record the distance between the centering flange nipple and the center of the locating bushing.
CAUTION:
A Torque wrench MUST be used when tightening the differential fixing bolts to 110 Nm (81 lbf.ft).
5. If the measurements remain unequal, loosen the snugged differential bolt and go to Step 2 to repeat the adjustment process for the desired
results.
6. When the recorded distance is equal above and below the locating bushing, tighten all differential bolts to 110 Nm (81 lbf.ft).
INSTALL THE PROPELLER SHAFT
1. Slide the propeller shaft forwards and remove the nut and bolt securing the centering flange to propeller shaft.
2. Remove the centering flange.
3. Remove the front propeller shaft.
4. Install a new 0 ring (TYX000070) to the drive tube.
CAUTION:
ONLY use grease TIA500010. Use of any other grease or lubricant will result in premature spline wear.
5. Lubricate the 0 ring running surface with grease from packet (TIA500010).
6. Evenly distribute all of the remaining grease in the packet onto the propeller shaft splines and the drive tube splines.
43
7. Install the propeller shaft into the differential drive tube.
8. Inspect the centering flange dust seal and install a new seal if indicated.
9. Clean the coupling and the centering flange mating faces.
10. Position the coupling and flange with arrows on coupling pointing towards the flange mounting. (Figure 8)
11. Install bolts securing the coupling and tighten new nuts to 110 Nm (81 lbf.ft).
12. Lower the vehicle onto its wheels.
13. Lower the lift.
14. Connect the battery ground cable.Land Rover Range Rover Technical Service Bulletin # 5403032 Date: 040220
Drivetrain - Front Differential Alignment Procedure
No: 54/03/03/NAS
Ref:
*Issue: 2
Date: 20 February 2004*
* asterisks shows updated information *
Front Differential Alignment Process
*NOTE:
The alignment process has been enhanced since the initial bulletin. Virtually all aspects of the bulletin have been revised. Please read the entire
process to familiarize yourself with the new conditions.
Because of the substantial changes throughout the procedure no additional "change shading" will occur in this bulletin.*
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
SITUATION:
ALIGNMENT FOR DIFFERENTIAL INSTALLATION REQUIRED
The required procedure for differential alignment during installation is not thoroughly covered in the RAVE Workshop Manual.
RESOLUTION:
FOLLOW DIFFERENTIAL ALIGNMENT PROCESS
For component longevity it is important that the differential and the transfer box front output flange are correctly aligned. A process and a special
measurement tool have been developed to ensure proper alignment of the transfer gearbox front output flange, propeller shaft and the front
differential whenever work has been conducted on these components.
CAUTION:
Any damage or wear to the differential drive tube splines, requires that the whole differential assembly be replaced as well as the prop shaft. The
differential assembly includes a collapsible spacer that determines the bearing preload. There is currently no acceptable procedure for renewing a
44
drive tube in service. If an attempt is made to change the drive tube only, rapid failure of the differential bearings will occur. Damaged or worn
splines in the drive tube will have affected the propeller shaft also, requiring replacement.
PARTS INFORMATION:
TOOLS
LRT54032K Propeller shaft alignment tool Refer to Service Bulletin STE03-20
WARRANTY CLAIMS:
DDW WARRANTY CLAIMS:
Differential Alignment
CAUTION:
When a new front differential is installed, the following alignment procedure MUST be carried out before fully tightening the differential bolts
and installation of the front propeller shaft.
NOTE:
This alignment procedure will be incorporated into the RAVE Workshop Manual at the next edition.
1. Remove and discard the 0 ring from the differential drive tube ("A" in Figure 1).
CAUTION:
All grease must be removed.
2. Thoroughly clean the differential drive tube splines ("B" in Figure 1) and the propeller shaft splines.
3. Install the propeller shaft to the differential drive tube.
45
4. Slide the propeller shaft forwards and fit the centering flange ("A" in Figure 2) to the propeller shaft.
5. Temporarily secure the centering flange with a suitable nut and bolt. ("B" in Figure 2)
6. Rotate the centering flange to allow the alignment tool to be placed in position (Figure 3).
7. Remove one slider from the alignment tool (LRT-54-032) and set aside.
8. Position the alignment tool into the bushing opening in the transfer gearbox front output flange. (Arrowed in Figure 3)
9. Using a 2 mm Allen wrench, loosen the slider screw so that the slider moves freely along the rule.
NOTE:
It may be necessary to slide the propeller shaft, together with the alignment tool, slightly forwards. This will allow the alignment tool to be
slightly extracted from the locating bush in the transfer gearbox front output flange, to allow clearance.
10. Slide the propeller shaft rearwards until the centering flange nipple is nearly in contact with the alignment tool surface. (Figure 4).
11. Position the alignment tool vertically with the slider below the centering flange nipple.
12. Gently pull the propeller shaft down to its lowest position.
13. Tighten the slider screw to identify the extent of movement.
NOTE:
The alignment tool may have to be rotated into a horizontal position to note the measurement.
14. Record the measurement on the alignment tool, at the inside edge of the slider. (Inset Figure 4).
15. Loosen the slider screw so that the slider moves freely along the rule.
46
16. Position the alignment tool vertically with the slider above the centering flange nipple.
17. Gently push the propeller shaft up to its highest position and move the slider down to the top of the centering flange nipple.
18. Tighten the slider screw using the Allen wrench.
NOTE:
The alignment tool may have to be rotated into a horizontal position to note the measurement.
19. Record the measurement on the alignment tool, at the inside edge of the slider. (Inset Figure 5)
20. If the recorded measured distances above and below the locating bushing are equal within 1 mm, the differential is correctly aligned to the
transfer box front output flange. Go to section "Install Front Propeller Shaft".
21. If the measured distances are not equal within 1 mm, go to section "Adjustment of Differential Alignment".
Adjustment of Differential Alignment
CAUTION:
Unequal alignment measurements as depicted in Figures 6 and 7 require differential alignment to the transfer box output flange.
NOTE:
Rotating the differential counter-clockwise will raise the drive tube. This will decrease the excess distance below the locating bush shown in the
example (Figure 7). This procedure may need to be repeated several times to achieve the desired result.
1. Slide the propeller shaft forwards, release the centering flange securing nut and bolt, rotate the centering flange and remove the alignment tool.
(Figure 3)
NOTE:
The calculated average measurement is the "target" position (maximum up and down) for the propeller shaft in relation to the locating
bushing in the transfer gearbox front output flange.
2. Calculate the average of the up and down recorded measurements to obtain the "target" measurement.
47
3. Release the slider screw on the alignment tool and move the inside edge of the slider to the calculated "target" position.
4. Fully tighten the slider screw with the Allen wrench.
5. Position the alignment tool into the transfer gearbox front output flange locating bushing. (Figure 8).
6. Rotate the centering flange into position and secure with a suitable nut and bolt.
7. Slide the propeller shaft rearwards until it contacts the face of the rule.
NOTE:
It may be necessary to slide the propeller shaft, together with the alignment tool, slightly forwards. This will allow the alignment tool to be
slightly extracted from the locating bush in the transfer gearbox front output flange, to allow clearance.
8. If the measured distance was larger below than above the centre line of the locating bushing, position the alignment tool vertically with the
slider above the centering flange nipple.
9. If the measured distance was larger above than below the center line of the locating bushing, position the alignment tool vertically with the
slider below the centering flange nipple.
NOTE:
The initial movement of the propeller shaft will be due to the fit of the propeller shaft and the drive tube mating splines. When
approaching the slider, resistance will be felt as the differential moves.
10. Perform differential alignment as follows:
^ Release the four differential attachment bolts sufficiently to secure the differential, but still allow slight rotation on its axis. (Figure 9)
^ Gently push the propeller shaft up or pull the propeller shaft down until the centering flange nipple touches the inside edge of the slider.
^ With assistance, hold the propeller shaft in this position and snugly tighten one of the differential bolts to secure the differential.
^ Verify the measurement above and below the centering flange nipple is equal and the same as the "target" measurement.
11. Repeat adjustments in step 10 up and down as required to achieve equal alignment measurements.
CAUTION:
A Torque wrench MUST be used when tightening the differential attachment bolts to 110 Nm (81 lbf.ft).
12. When the measurement is equal above and below the locating bush within 1 mm of the "target" position, tighten all bolts securing the front
48
differential to 110 Nm (81 lbf.ft).
13. Verify that the measurement above and below the centering flange nipple remain equal after the torque procedure.
Propeller Shaft Installation Procedure
1. Slide the propeller shaft forwards and remove the nut and bolt securing the centering flange to propeller shaft.
2. Remove the centering flange.
3. Remove the front propeller shaft.
CAUTION:
ONLY use grease TIA500010. Use of any other grease or lubricant will result in premature spline wear.
4. Lubricate the 0 ring running surface with grease from packet (TIA500010).
5. Evenly distribute all of the remaining grease in the packet onto the propeller shaft splines and the drive tube splines.
6. Install the new "0" ring (TYX000070) into the drive tube. (Figure 10)
7. Install the propeller shaft into the differential drive tube.
8. Inspect the centering flange dust seal and install a new seal if indicated.
9. Clean the coupling and the centering flange mating faces.
10. Position the coupling and flange with the arrows on the coupling pointing towards the flange mounting. (Figure 11)
11. Install bolts securing the coupling and tighten new nuts to 110 Nm (81 lbf.ft).
12. Lower the vehicle onto its wheels.
13. Lower the lift.
14. Connect the battery ground cable.Land Rover Range Rover Technical Service Bulletin # TEC540104 Date: 040820
Drivetrain - Front Differential Breather Pipe Oil Leaks
No: 54/01/04/NAS
Ref:
49
Issue: 1
Date: 20 August 2004
Oil Leak From Front Differential Breather Pipe
AFFECTED VEHICLE RANGE:
New Range Rover (LM)
ALL
SITUATION:
OIL LEAK FROM FRONT DIFFERENTIAL BREATHER PIPE
The customer may complain of an oil leak from under the engine bay area of the vehicle. There are a couple of potential reasons for a differential
related oil leak:
^ The front differential breather pipe adaptor may be oriented in the wrong direction.
The differential may be slightly overfilled with oil.
NOTE:
The position of the filler plug in the front differential does not correspond with the fill level required to ensure component protection while
avoiding oil expulsion from the breather pipe.
RESOLUTION:
ENSURE BREATHER PIPE ADAPTER IS CORRECTLY ORIENTED
Upon customer complaint of the above symptoms, follow the procedure below to confirm the correct orientation of the breather pipe adapter and
ensure proper fill level in differential.
^ If the breather position is incorrect, replace the differential assembly.
^ If position is correct, drain the differential assembly and refill following the revised Workshop Manual procedure.
PARTS INFORMATION:
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply. Material allowance is included in labor operation.
REPAIR PROCEDURE
INSPECT POSITION OF BREATHER PIPE
NOTE:
It is possible to confuse a camshaft cover leak with a differential breather leak. Always ensure a thorough inspection to verify the leak source.
1. Remove the acoustic cover and locate the differential breather pipe.
50
2. Inspect for evidence of a differential breather leak such as oil residue present around the breather pipe where it connects to the breather
adaptor. (Figure 1)
3. If evidence of a differential oil leak is found, follow the check orientation - breather pipe adaptor procedure.
CHECK ORIENTATION - BREATHER PIPE ADAPTER
1. Raise the vehicle on a lift.
2. Remove the left hand front road wheel.
3. Clean area surrounding the breather pipe adapter.
NOTE:
The straight edge on the differential breather pipe adaptor must be facing towards the front of the vehicle.
4. Determine if the front differential breather pipe adapter is in the correct orientation. (Figure 1).
NOTE:
GTR lookup sequence is as follows:
GTR Home> NAS > Service Information/ LM Range Rover 2005 > Workshop Manuals > Service Procedures > Bookmark "Front
Differential/Adjustments/ Drain and Refill"
CAUTION:
Lubricant must be refilled to a precisely measured volume of 750ml (25.4 oz) for refill of the front differential.
5. If the differential breather pipe adapter is in the correct orientation, drain and refill the front differential.
CAUTION:
The breather pipe adapter cannot be reoriented in the differential housing without damaging the housing.
6. If the differential breather pipe adaptor is NOT in the correct orientation, refer to GTR section 54.10.01 and perform the following:
^ Replace the front differential assembly with a new assembly.
Align differential following procedures in referenced section 54.10.03.01.
CAUTION:
Lubricant must be filled to a precisely measured volume of 800m1 (27oz) when replacing the front differential with a new assembly.
^ Fill the new front differential assembly with lubricant (LRN7591) following the revised procedure in GTR section 54.15.02.
7. If a refill was performed, disconnect the breather pipe from the front differential.
8. Blow compressed air through the disconnected breather pipe to clear any residual oil.
9. Connect the breather pipe to properly filled new or refilled differential.
10. Ensure the area is free from oil residue.
11. Install the acoustic cover.
12. Install the left hand road wheel and tighten nuts to 140 Nm (103 lbf.ft).Land Rover Range Rover Technical Service Bulletin # G97-028 Date: 971031
A/T - Filter Replacement Interval
Section: General Information
51
Date: 31 October 1997
Model: All
Applicable to: USA/Cda
Subject: Automatic Transmission Filter Replacement Interval
Service Bulletin G97-027 introduces new Maintenance Schedules for the Land Rover product line which simplify the routine maintenance
requirements for all models.
We wish to call to your attention to one of the important changes found in these revised schedules:
^ Effective with this Service Bulletin, the requirement for Automatic Transmission filter replacement has been reduced to once over the lifetime of
the transmission. The change is to be performed at the 30-thousand mile service.
^ All Land Rover products equipped with the ZF automatic transmission produced since 1987 benefit from this change in policy. Reduced
maintenance costs for owners of older Land Rover product is one of the key benefits of this change in policy.
ZF has advised Land Rover that a filter change after the 30-thousand mile service is required only if there is reason to believe the fluid has become
contaminated. If you have questions regarding this matter please contact your Product Support Representative.
Land Rover Range Rover Technical Service Bulletin # TEC4402002 Date: 010615
A/T - Fluid Leaks From Torque Converter
No: 44/02/00/NAS
*Ref:
Issue: 2*
Date: 06/15/01
Transmission Oil Leak
AFFECTED VEHICLE RANGE:
Range Rover 4.6 (LP) All up to Transmission # 288455
Range Rover 4.0 (LP) All up to Transmission # 1804335
Discovery Series II (LT) All up to Transmission # 1804335
Discovery (LJ) All
Defender (LD) All
* indicates updated information
SITUATION:
OIL LEAK IN TORQUE CONVERTER OR INTERMEDIATE PLATE AREA
A transmission oil leak might develop in the torque converter or intermediate plate area. The cause may be oil seepage through the thread of bell
housing mounting bolts.
RESOLUTION:
SEAL BOLT THREADS AND INSTALL NEW GASKET
Replace the intermediate plate gasket and apply Loctite(R) 243 to five of the bell housing mounting bolts as specified in the Procedure section of this
TIB.
PARTS INFORMATION:
RTC4320 GASKET Qty 1
LRN24078 Loctite 243 Sealant & Thread locker
WARRANTY CLAIMS:
*NOTE:
On any Transmission exhibiting these symptoms AFTER the transmission numbers listed above ensure the ATER is completed and that the ZF
HelpLine has been consulted for a repair authorization.
No authorization is required on transmissions included in the "Affected Vehicle Range" listing above.*
52
44.20.11 Time 6.35 hrs. Range Rover Classic
Time 5.95 hrs. Discovery
Time 7.50 hrs. Defender 90
Time 6.40 hrs. Discovery Series II
Reseal bell housing/intermediate plate mounting bolts on 4HP-22
44.20.11 Time 6.90 hrs. Range Rover 4.0/4.6 up to 1998
Time 7.30 hrs. Range Rover 4.0/4.6 1999 and up
Reseal bell housing/intermediate plate mounting bolts on 4HP-24
FAULT CODE: N
Normal warranty policy and procedures apply
REPAIR PROCEDURE
1. Refer to the WSM Section 44.20 and remove the transmission from the vehicle.
2. Remove the torque converter.
CAUTION:
The 6 bolts that mount the bell housing to the intermediate plate must remain installed.
3. Remove the 12 bolts that hold the bell housing/intermediate plate assembly to the transmission case.
CAUTION:
The input shaft and clutch A assembly must not be disturbed in the following steps.
4. Carefully remove the bell housing/intermediate plate assembly.
5. Remove the old intermediate plate gasket
NOTE:
A light coat of Vaseline may be used to hold the gasket and end-lay adjustment shim in position during assembly.
6. Place the new gasket (RTC4320) on the intermediate plate.
7. Place the transmission endplay adjusting shim on the intermediate plate stator shaft.
CAUTION:
Loctite 243 will work only when applied to an oil free surface.
NOTE:
Some of the bell housing/intermediate plate mounting bolts might have Hylomar applied to the thread.
8. Clean the threads of all mounting bolts.
9. Clean all Hylomar and all oil residues from the threads in the transmission housing.
53
10. Install the bell housing/intermediate plate assembly.
11. Apply a moderate amount of Loctite 243 to the threads of 5 mounting bolts.
12. Refer to Figure 1 and install the 5 bolts in the location shown.
13. Install the rest of the mounting bolts.
14. Tighten all bolts hand tight, then torque to 46 Nm (34 lbf.ft.).
CAUTION:
Care must be taken when installing the torque converter to avoid damage to the pump seal or pump drive gear. In this procedure there is no
need to replace the pump shaft seal.
15. Carefully install torque converter.
16. Install the transmission into the vehicle following WSM procedures.
Land Rover Range Rover Technical Service Bulletin # TEC440299 Date: 991022
A/T - Cooler Flushing
No: 44/02/99/NAS
Ref:
Issue: 1
Date: 10/22/99
Transmission-Cooler Flushing Kit
AFFECTED VEHICLE RANGE:
All vehicles equipped with automatic transmissions
SITUATION:
CONTAMINATION OF REPLACEMENT TRANSMISSION
When a transmission is replaced, it is possible that contaminants present in transmission lines and cooler as the result of mechanical failure, could
damage the replacement transmission.
RESOLUTION:
FLUSH TRANSMISSION LINES AND COOLER
NOTE:
Use of the flushing kit will be authorized by the Technical HelpLine when an ATER authorization is made for vehicles covered by warranty.
To prevent premature failure of a replacement transmission, the lines and cooler must be flushed to remove any contaminants remaining from the
damaged unit. A transmission cooler flushing kit has been developed, and should be used before installation of a replacement transmission required
as the result of mechanical failure.
PARTS INFORMATION:
ERR3340 Land Rover oil filter (Not included in kit)
TOOLS
NOTE:
Transmission-Cooler flushing kit will be shipped directly from Kent-Moore. All questions concerning missing shipment and damaged tools
should be directed to the Kent-Moore Helpdesk.
LRA-44-001 Transmission Flushing Kit
^ Oil filter-mounting base Qty. 1
^ Rubber hose Qty. 2
^ Adapter fitting male Qty. 1
^ Adapter fitting female Qty. 1
^ "S" hooks Qty. 2
^ Chain Qty. 1
WARRANTY CLAIMS:
54
44.24.50/01 Time 0.40 hrs.
Flush transmission lines and cooler
FAULT CODE: K
Normal warranty policy and procedures apply
REPAIR PROCEDURE
FLUSH TRANSMISSION LINES AND COOLER
NOTE:
When installing replacement transmission, do not connect cooler return line. This line attaches to the inlet port on the bottom of the transmission
and will be used as the location for the flushing filter.
1. Refer to WSM and install new transmission.
2. Verify that transmission is in park.
3. Set the parking brake.
CAUTION:
The flushing tool oil filter must be replaced each time the flusher is used.
4. If the old filter or filter gasket is present, remove from the adapter mounting base.
5. Lubricate the new oil filter gasket with clean transmission fluid.
6. Install the new oil filter on the filter-mounting base.
7. Determine inlet side of filter mount by locating inlet arrow. (Figure 1)
8. Connect cooler/transmission line to rubber inlet hose on transmission-flusher-filter-mounting base. (Figure 1)
55
9. Connect the outlet hose from the transmission-flusher-filter-mounting base to the transmission inlet. (Figure 2)
10. Secure filter/hose assembly to the chassis using chain and hooks provided with kit.
11. Verify that the rubber hoses are routed away from moving parts and exhaust components.
12. Refer to WSM and fill transmission with approved ATF.
13. Verify that handbrake is set and transmission is in park.
14. Start engine and check for leaks at all flusher fittings.
15. Apply foot brake.
16. Move gear selector lever though all gear positions.
17. Place gear selector in "P" (Park).
18. Let the engine idle for four minutes.
19. Turn off engine.
20. Disconnect the flusher assembly and all related hoses.
21. Install new O-rings onto transmission cooler pipe.
22. Install cooler pipe and torque fitting to 30 Nm (22 lbf.ft).
23. Refer to WSM and check transmission fluid level.
24. Discard used oil filter in accordance with local regulations.
25. Wipe off filter base and hoses and store in plastic case.
Land Rover Range Rover Technical Service Bulletin # 17-01-96 Date: 961231
HO2S - Handling and Diagnostic Procedures
17/01/96/US
12/31/96
SUBJECT
PRIDE - HO2S: Handling and Diagnosis
MODEL
Range Rover 4.0/4.6
Discovery
Discovery
AFFECTED VEHICLES
LP SA302084 onwards
LH
LJ TA166228 onwards
LJ TA502787 onwards
DETAIL
The Heated Oxygen Sensor (HO2S) is used to supply the ECM with information used to modify the operation of the fuel and ignition system for the
best economy and emission performance. The HO2S measures the amount of oxygen in the exhaust stream as an indication of combustion efficiency.
When the engine is running rich there is very little oxygen in the exhaust, and vice versa.
The H02S operates on a principle similar to temperature sensors. However, unlike like the temperature sensors, the H02S switches quickly as the 02
content of the exhaust changes. The speed of switching is a measure of the serviceability of the sensor. The GEMS sensors have a separate heater
circuit. The sensor will not operate correctly if the heater is not working. Power for the heaters is supplied whenever the key is in the ON position.
56
The ground side of the heater circuit is controlled by the ECM and is switched on and off while the engine is running to maintain a consistent sensor
tip temperature.
When oxygen sensor P-codes are retrieved from TestBook, the Bear Analyzer's Uniscope function can be used in determining if these oxygen sensor
P-codes were caused by the sensor or something upstream of the sensor (i.e. engine, mechanical or fuel system problems, etc.). When no faults are
found after diagnosis of the system, the Snap Throttle test will show if the sensor is capable of operation in normal driving conditions. If the sensor
proves good with this test you should look for the problem elsewhere (i.e., an exhaust leak).
NOTE: The snap throttle test is applicable to upstream sensors only. However, the downstream sensors can be diagnosed if they are moved into the
upstream position.
The diagnostic steps and repair procedures detailed on the following pages were developed as an element of the Land Rover Way OPERATION
PRIDE. This TIB provides a library location for PRIDE information within the Land Rover North America technical literature system.
ACTION REQUIRED
If oxygen sensor P-codes are retrieved, thoroughly check the four heated oxygen sensors (H02S) as outlined below. Then if necessary, perform the
snap throttle test on Upstream sensors.
PARTS INFORMATION
ERR1834 - Heated Oxygen Sensor
WARRANTY
Normal warranty policy and procedures apply.
COMP. CODE
SRO
19.22.16: H02S renew front - 0.35 hr
19.22.16.01: H02S renew rear - 0.35 hr
19.22.96: TestBook hook-up, access codes, complete DTCR, and diagnostic drive cycle C (service bulletin W96-007) - 1.25 hrs
19.26.26: TestBook access codes, Uniscope analysis, DTCR, & drive cycle C
19.22.89.29: Snap Throttle test - 0.25 hr
* A 0.05 hr time allowance can be claimed for each P-code found using the appropriate SRO code. (EX. If P-code 1137 is stored. use SRO
19.22.1137.
PROCEDURE
IMPORTANT: The HO2S sensors used on Land Rover GEMS equipped vehicles are very fragile. It is important that the proper handling
guidelines are observed.
The most common sensor used is zirconium based and generates a voltage of up to 1 volt based on the difference between the oxygen in the exhaust
stream and that of the atmosphere.
Land Rover vehicles use a titania based sensor that operates differently. Instead of producing a voltage, the sensor changes resistance in response to
oxygen in the exhaust. A rich mixture creates a low resistance in the sensor and vice versa.
A five volt reference signal is supplied to the sensor. In the case of a rich mixture, the low resistance in the sensor "pulls" the voltage low.
Conversely, a lean (high oxygen content); mixture will cause the sensor to have high resistance and a high voltage. The typical range on a GEMS
equipped vehicle is between less than 1 volt to more than 4 volts.
NOTE: Older vehicles have a three wire sensor that operates on a similar principle with different wiring and different voltage ranges.
DIAGNOSIS
1. Attach TestBook and pull Diagnostic Trouble Codes (DTC).
2. Access Freeze-Frame data. Fill out DTCR and FAX to LRNA at (301) 731-9814
3. Check the operation of the sensors using Multiple Real Time Monitoring on TestBook.
4. Start engine and set engine to about 2500 rpm for 2 or 3 minutes.
NOTE 1: When the catalytic converters start to operate as the engine warms up, the downstream sensors will not react the same as the upstream
sensors if the converters are operating properly.
NOTE 2: A fixed voltage of 4.99 volts indicates an open circuit in the sensor or sensor circuit
5. Observe HO2S switching activity. The sensors should be switching rapidly between 0 volts and 5 volts Go to Oxygen Sensors/Fuel screen for
57
a faster reading from individual sensors if necessary.
6. If the sensor is not responding, check the heater operation. The heaters are wired in upstream and downstream pairs. A bad heater will result in
a lower voltage displayed in real time. Follow circuit checks below to diagnose.
7. Replace any sensor which is not switching properly.
INSPECTION
1. When sensor voltages do not switch or appear intermittent, the ECM harness connector terminal may have become loose.
2. Disconnect harness and carefully examine the connector terminals.
3. If they are found to be loose, release the terminal from the connector. Press down on tab with a suitable blunt object (ball point pen) enough to
restore the terminal tension. While terminal is out, examine closely.
4. If any corrosion is evident, clean terminal with a suitable electrical contact cleaner.
5. If water intrusion is apparent, check connector gasketing, and repair as necessary.
6. Make sure that under body connectors are firmly held in the wire guiding clips and are not allowed to dangle loosely.
7. As in the ECM harness check, examine the connectors for corrosion or looseness.
8. While connectors are apart,
CONNECTOR INSPECTION
When a sensor fault is stored but the sensor appears to operating normally, it would be useful to check the HO2S wiring. Refer to the Operation
Pride Manual for the Discovery and Range Rover circuit diagrams.
IMPORTANT: Use extreme care when handling the sensor. Do not drop or physically damage the sensor. If sensor has been dropped, do not
install on vehicle.
REMOVAL AND INSTALLATION
1. Remove any dirt or debris in the vicinity of the sensor to avoid contamination in the catalytic converter or the threads in the exhaust pipe.
2. Verify vehicle is not at operating temperature.
3. Remove old sensor.
4. Apply anti-seize to the threads of the new sensor, taking care that no anti-seize contaminates the sensor tip.
5. Install sensor and finger-tighten in the exhaust pipe.
IMPORTANT: Proper torquing of the sensor is critical. Experience has shown that if the sensor is over-torqued, there is a possibility that the body
of the sensor element can distort, causing a cracked sensor element. Use the proper tool and the proper torque specification.
6. Using special tool # LRT - 12-O47, tighten sensor to 20 Nm, (15 lb.ft).
Retest After Repair
1. Clear any codes that may have been stored with Testbook.
58
2. Perform drive cycle C. (Refer to service bulletin W-96-007).
2. Recheck with TestBook for any newly stored codes.
3. If codes were stored, proceed with the Snap Throttle test.
After retrieving oxygen sensor P-codes from GEMS, go to real time monitoring oxygen sensors/fueling and check voltage activity of sensors as well
as sensor heaters. If you observe that the voltage is fixed at 4.8 or 1.0 volts. then rev the engine several times quickly and see if the voltages begin
switching. A sensor that does not respond will be defective or have a connection problem. Thus it is unnecessary to proceed with the oxygen sensor
"snap throttle" test below.
If the sensor is not responding, check the heater operation. The oxygen sensor heaters maintain the tip of the sensors at their optimum operating
temperature. The two front heaters are driven in parallel as are the two rear heaters. The heater voltages shown in Real Time Monitoring are used by
the ECM to check the temperature of the heaters. when the engine is warm, these voltages will settle to approximately 1 volt.
NOTE: A voltage of approximately 0.5 volts could be caused by one open circuit heater. Follow the circuit checks to diagnose open circuit
IMPORTANT: A good sensor must meet all these specifications, provided the procedures were followed exactly as Outlined. If the engine idles
too long, the sensor may cool down too much. This can lower its maximum voltage and increase its response time, causing a possible test failure.
Many sensors will perform adequately when very hot (after 2-3 minutes at 2500 rpm), but will fail when cool. Others may fail at high temperatures.
Check in both conditions.
SNAP THROTTLE TEST OF UPSTREAM SENSORS USING BEAR ANALYZER "UNISCOPE"
NOTE: If pinging is encountered while performing the Snap Throttle Test, poor fuel quality is usually the cause. This must be remedied before
proceeding with test.
1. Calibrate lead set for accurate voltage readings.
2. Switch off A/C compressor.
3. Set Uniscope red channel on ± 7 VDC and 32 ms.
4. Back probe pin 33 of red 36 pin connector for bank B, or pin 34 for bank A sensors.
5. Run engine to operating temperature (approx. 195°F) then heat engine and HO2S's fully by running engine 2-3 minutes at 2500 rpm. Let idle
for 5 seconds but no more than 20 seconds.
6. Push record on Uniscope.
7. Rev the engine rapidly four to five times in 2 second intervals from idle to wide open throttle (do not exceed 300 rpm).
8. Examine recording frame by frame. set cursor # 1 at maximum HO2S voltage and take a reading; record maximum voltage results. Set cursor
# 2 on minimum HO2S voltage and record results.
9. Measure rich-lean response times.
NOTE: Do not judge response times at the beginning of the record cycle (i.e. frames 1-3).
10. Print screens using print icon on upper right corner of screen.
59
60
Land Rover Range Rover Technical Service Bulletin # TEC190301 Date: 010713
Engine Controls - MIL ON/MAF Multiple DTC's Set
No: 19/03/01/NAS
Ref:
Issue: 1
Date: 07/13/01
MIL Event from Mass Air Flow Sensor
AFFECTED VEHICLE RANGE:
Range Rover (LP) From XA410504 - All Bosch EMS
Discovery Series II (LT) All
SITUATION:
MIL ILLUMINATION: FAULT CODES INDICATE MASS AIR FLOW SENSOR PROBLEMS
Unfastened clips, improper sealing or incorrect filter installation can allow unfiltered air and dirt into the intake. This uncontrolled air flow can result
in MIL illumination and Mass Air Flow (MAF) adaption faults and eventually to sensor contamination.
RESOLUTION:
PROPER INSTALLATION OF FILTERS AND SEALS
61
Correct maintenance of the air intake system includes the replacement of the air filter in compliance with the maintenance schedule. More frequent
replacement may be required in extreme use conditions, such as deep water wading or desert driving.
Whenever the filter is replaced, careful execution of the replacement installation is required. It is particularly important that the air filter box cover
and locking clips are fitted correctly after the air filter element has been changed. It is also possible for the "O" ring seal between the air filter box
and the MAF sensor housing to be damaged during the filter change.
PARTS INFORMATION:
Range Rover
PHB102260 Air Filter Housing Assy. Qty 1
^ ESR4238 Air Filter Qty 1
^ PHN100220 Seal Ring Qty 1
MHK100800 MAF Sensor Assy. Qty 1
Discovery Series II
ESR4237 Air Filter Housing Qty 1
^ ESR4238 Air Filter Qty 1
^ PHN100200 Seal Ring Qty 1
ERR7171 MAF Sensor Assy. Qty 1
Contaminated MAF components will require replacement.
WARRANTY CLAIMS:
Claim operation times for Air Filter replacement, MAF sensor replacement and Drive Cycle "C" as appropriate.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
MIL INVESTIGATION AND AIR LEAK CORRECTION
1. Investigation of a MIL event may reveal a range of faults possibly related to uncontrolled air intake:
^ Fuelling adaptions codes (P0171, P0172, P0174, P0175)
^ MAF sensor plausibility codes (P0101, P0102, P0103)
^ Throttle angle plausibility codes.
CAUTION:
It is important that the air filter box cover and locking clips are fitted correctly when the air filter element is changed. Care must be taken
to avoid damage to the O-ring seal between the air filter and the MAF Sensor during the filter change.
2. Inspect the air filter housing for correct alignment between the upper and lower portions.
3. Inspect the O-ring to the MAF sensor for damage.
4. If damage found, replace O-ring.
5. If an uncontrolled air leak is determined, correct the air leak as follows:
^ Clean the airbox of any foreign materials.
62
^ Refer to the Workshop Manual Section 19.10.10 and carefully install a new filter. (Figure 1)
^ Verify proper fit of the cover to the filter housing.
^ Install and latch the airbox cover. (Figure 2)
6. If the filter housing cannot be correctly aligned to the filter or the top cover, replace the filter housing.
7. Clear all P-codes.
8. Allow vehicle to idle with the A/C off for 30 minutes to allow FRA/TRA adaptions to adjust.
9. Check for P-Codes.
10. Perform Drive Cycle "C" to validate
11. If no P-codes are set during Drive Cycle "C," the fault was in the filter installation. No additional action is required.
NOTE:
ONLY if plausibility P-codes are set during the drive cycle with a properly fitted filter and a sealed airbox is MAF sensor contamination
indicated as the root cause of the codes.
12. If P-codes are set, refer to the Workshop Manual Section 19.22.25 and replace the MAF sensor unit.
13. Install the filter and housing correctly to prevent uncontrolled air ingress.
14. Clear codes and verify repair by followings steps 8-10 above.
Land Rover Range Rover Technical Service Bulletin # TEC510200 Date: 000512
Drivetrain - Rear Axle Clicking Noise
No: 51/02/00/NAS
Ref: 51/01/98/NAS
Issue: 1
Date: 05/12/00
63
Click Noise from Rear Axle Area
AFFECTED VEHICLE RANGE:
Hub/Axle Shaft
Range Rover (LP) Up to YA434637
Differential Pinion Flange
Range Rover (LP) Up to YA435750
Discovery II (LT) Up to YA260194
Up to XA907212
SITUATION:
REAR AXLE CLICKING NOISE
When moving the gear selector lever from the "D" (drive) position to "R" (reverse) or from "R to "D" a clicking noise may be heard from the rear
axle area. The noise may be the result of movement between the axle shaft spline and the drive flange. The differential flange to pinion spline can
exhibit the same symptoms.
RESOLUTION:
NOTE:
This TIB supersedes and replaces the information contained in TIB 51/01/98/NAS SECURE AXLE SHAFT SPLINE TO HUB JOINT
When a customer complains of these symptoms, or if the axle is apart for other work, Range Rover vehicles prior to the above VIN should have the
axle shaft spline-to-hub joints secured using Loctite 648. Apply the Loctite using the procedure outlined below.
The rear differential flange to pinion spline for Range Rover and Discovery Series II models up to the above VINs can be corrected for a "click"
sound with assembly using Loctite 648 also. When a vehicle after the above VINs is disassembled for repair, Loctite 648 should be used as part of
the assembly process.
PARTS INFORMATION:
CDU1534L Stake Nut Qty. 2
NY116041L Nyloc nut Qty 1 Rear Differential flange RR up to VA37071
FS112301P Bolt Qty 1 Rear differential flange
Locally Sourced:
^ Loctite 648
WARRANTY CLAIMS:
64.15.01 Time 1.15 each side Range Rover only
Rear hub installation with Loctite
51.15.36 Time 0.55 Range Rover
Differential flange installation with Loctite
51.20.01 Time 0.50 Discover Series II
Differential flange installation with Loctite
FAULT CODE: G
Normal warranty policy and procedures apply
REPAIR PROCEDURE
NOTE:
Loctite has been applied to Discovery II rear hub splines since the introduction of the model. Should a Discovery Series II rear hub be
dismantled for any reason, regardless of VIN, Loctite 648 should be used during assembly as detailed below.
CLICKING NOISE FROM REAR AXLE SHAFT TO HUB SPLINE
CAUTION:
Care must be exercised when disassembling the axle assemblies to avoid damage to the oil seal.
1. Refer to WSM Section 64.15.01 and disassemble rear axle.
64
2. Remove axle shaft from hub assembly to expose shaft splines.
3. Thoroughly clean & degrease the shaft and flange spline.
CAUTION:
Ensure that only the spline area is covered when applying the Loctite 648. Ensure that from this stage the repair can be completed without
delay so that work is completed within Loctite 648 cure time.
4. Apply Loctite 648 to the shaft spline taking care not to coat beyond the spline area. (Figure 1)
5. Reassemble shaft to flange assembly.
6. Install new stake-nut (CDU1534).
7. Tighten the nut to initial torque of 100 Nm (75 lbf. ft.).
CAUTION:
Exercise care to avoid damage to the oil seal during axle assembly process.
8. Carefully refit hub and shaft assembly to axle case.
9. Install tires and lower vehicle to the ground.
NOTE:
The torque value given in the next step is increased over the value in the Workshop Manual.
10. Torque stake-nut to 340 Nm (250 lbf. ft.) and stake the nut.
11. Allow the Loctite 2 hours to cure before driving the vehicle.
CLICKING NOISE FROM REAR DIFFERENTIAL FLANGE TO PINION SPLINE:
CAUTION:
Care must be exercised when removing the flange to avoid damage to the oil seal.
1. Refer to Workshop Manual repair number 51.20.01 and remove pinion flange taking care not to damage the seal.
2. With pinion flange removed, thoroughly clean and degrease the pinion shaft and flange spline.
NOTE:
Ensure that from this stage the repair can be completed without delay so that work is completed within Loctite 648 cure time.
65
3. Apply Loctite 648 to the pinion shaft spline ensuring that only the spline area is coated. ("B" in Figure 2)
CAUTION:
Range Rover vehicles up to VIN VA370719 have pinion flanges secured with a nut. Later vehicles use a flange bolt, (refer to Figure 2). It
is essential that each fastener type be tightened to the correct torque as specified below.
4. If pinion flange is secured by a bolt, install flange and tighten the bolt to 100 Nm (73.8 lbf.ft.).
5. If pinion flange is secured with a nut, install flange and tighten the nut to 135 Nm (99.5 lbf.ft.).
6. Allow 2 hours for the Loctite to cure before driving vehicle.
Land Rover Range Rover Technical Service Bulletin # TEC120499 Date: 990903
Engine - Whining Noise
No.: 12/04/99/NAS
Ref:
Issue: 1
Date: 09/03/99
RH Serpentine Belt Idler Pulley Noise
AFFECTED VEHICLE RANGE:
Range Rover (LP) XA410483 onwards
SITUATION:
WHINE FROM UNDER THE HOOD AT IDLE
A customer may complain of a whining noise which disappears when the engine speed is raised above approximately 1100 rpm.
The alternator may be mistakenly identified as the source of this noise.
RESOLUTION:
REPLACE AUXILIARY DRIVE SYSTEM COMPONENTS TO RESOLVE RESONANCE
On customer complaint of the whining noise, investigate the source. Upon determination that the idler pulley is at fault, replace the auxiliary drive
belt and idler pulley with the specified parts.
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PARTS INFORMATION
TOOLS REQUIRED
WARRANTY CLAIMS
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
NOTE:
All vehicles have two idler pulleys. Only the pulley adjacent to the drive belt tensioner is to be replaced. That pulley is indicated with an
arrow in the illustration.
1. Refer to Figure 1 item A and verify that the idler pulley is the source of the noise.
2. Refer to Workshop Manual repair sections 26.25.19 and 86.10.03 for 99MY vehicles and disassemble the idler pulley and belt system as
follows:
^ Remove the cooling fan assembly using special tools LRT-12-093 and LRT-12-094.
^ Remove the bolts securing the drive belt cover.
^ Release the drive belt tensioner.
^ Remove and discard the used belt.
^ Remove and discard the RH idler pulley.
3. Clean all pulley grooves in all locations.
4. Inspect and verify that there is no damage to any groove in the belt pulley system.
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5. Install new idler pulley provided in kit PQZ100050.
6. Torque the idler pulley retaining bolt to 50 Nm (37 lbf.ft.).
7. Refer to WSM and install the new belt provided in kit PQZ100050.
8. Install the cooling fan assembly.
9. Verify that the noise has been eliminated as follows:
^ Start the engine and let the idle stabilize.
^ Determine that whining noise is not present.
^ Raise the engine speed gradually to 2000 RPM.
^ Allow the engine speed to stabilize at idle and remain at idle for 1 minute.
^ Verify that whining noise does not occur.
^ Repeat the elevation of engine speed up to 2000 RPM and listen for one more minute to ensure noise level is stable and whine noise has
been eliminated.
Land Rover Range Rover Technical Service Bulletin # D2163 Date: 001208
Recall - Engine Idler Pulley Replacement
No: D216
Ref:
*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:
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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 RoverQty 1 With 70 mm RH pulley*
*PQS101630 Polyvee Belt Range RoverQty 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.
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70
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^ 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.
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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
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2. Peel the label back, apply to radiator support and roll the label with the special roller.
Land Rover Range Rover Technical Service Bulletin # TEC8602033 Date: 030523
Engine - Idler Pulley/Belt Noise
No: 86/02/03/NAS
Ref:
*Issue: 3
Date: 05/23/03*
Serpentine Belt Idler Pulley Noise
* indicates updated information
AFFECTED VEHICLE RANGE:
Range Rover (LP) XA410504 and up
Discovery Series II XA200419 - 1A299999
1A700000 - 3A781991
SITUATION:
*NOTE:
Original versions of this bulletin used the incorrect term "tensioner pulley" to describe the part to be replaced. Both the terminology and the SRO
are corrected in Edition 3.*
NOISY AUXILIARY DRIVE BELT IDLER PULLEY
The customer may complain of a chirp or excessive belt noise. The plastic idler pulley may be deformed causing uneven loads on the serpentine belt.
RESOLUTION:
REPLACE DEFORMED PULLEY
Where a complaint of the above is confirmed, replace the auxiliary drive belt idler pulley with a new specification pulley.
PARTS INFORMATION:
PQR5OOO6O Idler Pulley
WARRANTY CLAIMS:
*NOTE:
The time associated with SRO 86.10.23 is the same as the originally published code.
86.10.23 Time 0.40 hrs.
Replace alternator drive belt idler pulley*
FAULT CODE: K
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
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*INSTALL NEW PULLEY
1. Refer to RAVE section 86.10.03 for affected vehicle and remove the auxiliary drive belt.
2. Remove bolt securing the RH idler pulley below the tensioner assembly.
3. Remove and discard the idler pulley.
4. Clean area around pulley mount and ensure mounting threads are clear of debris.
5. Install the new idler pulley and tighten the bolt to 50 Nm (37 lbf.ft).
6. Install the auxiliary drive belt following RAVE procedures.*Land Rover Range Rover Technical Service Bulletin # TEC7001003 Date: 010406
Brakes - Rear ABS Sensor Signal Fault
No: 70/01/00/NAS
Ref:
*Issue: 3
Date: 04/06/01*
ABS Sensor Sealing Boot Installation
AFFECTED VEHICLE RANGE:
Range Rover (LP) All
* indicates updated information
SITUATION:
REAR ABS SENSOR SIGNAL FAULT
Under certain weather conditions the rear ABS sensor can be "lifted" away from the reluctor ring, reducing sensor sensitivity and ultimately causing
the ABS system to set a fault. Water ingress or other contaminants around the sensor housing can also cause corrosion of the toothed reluctor ring,
causing signal errors.
RESOLUTION:
INSTALL NEW ABS SENSOR SEAL
A new rubber sensor seal has been developed to ensure proper protection of the rear sensors. A properly sealed sensor reduces contamination or the
tendency for the sensor to back out of the axle housing during adverse weather conditions.
PARTS INFORMATION:
SSV000010 ABS Sensor Seal Qty 2 - 1 per sensor
WARRANTY CLAIMS:
70.65.89/31 Time 0.80 hrs.
Install new rear ABS sensor seals
FAULT CODE: U
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Normal warranty policy and procedures apply
REPAIR PROCEDURE
INSTALL NEW REAR ABS SENSOR SEALS
1. Refer to WSM Sections 70.65.33 for instructions on removal of ABS sensors from rear axle locations.
* NOTE:
Sensor collar needs to be replaced only on vehicles above 12,000 miles.*
2. Remove each sensor and seal and discard the old seals.
* WARNING:
Always wear eye protection when cleaning contaminants from axle cavity.*
3.* Using compressed air, blow out any contaminants from the axle housing.*
4. Apply sensor grease to inside of sensor bore with application brush.
5. Install new sensor seal to collar. (Figure 1)
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6. Refer to WSM section 70.65.33 and install sensor, pushing sensor home until contact is made with the reluctor ring.
7. Verify that the new seal is properly seated.
Land Rover Range Rover Technical Service Bulletin # TEC700405 Date: 050721
ABS - ABS/HDC Warning Lamp ON
No: 70/04/05/NAS
FGN LM206-07
Replaces: 70/11/04/NAS
Issue: 1
Date: 21 July 2005
Water Ingress into ABS Modulator
Connector
AFFECTED VEHICLE RANGE:
Range Rover (LM) Up to 4A161678
SITUATION:
ABS/HDC WARNING LIGHT ILLUMINATION
Water can enter the ABS modulator connection through the ground eyelet crimp under sustained usage in conditions of high water, particularly
fording streams. The water ingress problem is more prevalent when the engine bay is hot. Water contamination can result in connector terminal
corrosion and the ABS/HDC warning light being displayed on the instrument pack.
RESOLUTION:
INSTALL NEW-SPECIFICATION GROUND WIRES OR CONNECTOR HARNESS
Should a customer express concern regarding the above, refer to the procedure in this TIB. Inspect the connector for corrosion and replace either the
ground leads and eyelet with a new set or if indicated the entire connector with a repair connector harness. The new configuration ground leads have
a crimp sealed ground eyelet.
PARTS INFORMATION:
DDW WARRANTY CLAIMS:
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.
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
INSPECT HARNESS CONNECTOR FOR CORROSION
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LM Range Rover/2004 > Workshop Manuals > Range Rover Workshop Manual Service Procedure
> Bookmark "BRAKES/REPAIRS" link "ABS Electronic Control Unit (ECU)"
1. Refer to GTR Workshop Manual Section 70.65.01 and after proper preparation disconnect the battery ground lead.
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2. Disconnect the ABS Modulator connector (C0506).
3. Inspect the ABS connector for corrosion at the ground wires (Cavity 1 and Cavity 5)
4. Inspect other wires in connector for signs of corrosion.
5. Inspect the ABS Modulator pins for signs of corrosion.
6. If ABS Modulator pins are corroded, clean the pins or if severely damaged, replace the modulator.
7. If only the connector ground wires are corroded go to "Install New ABS Connector Ground Leads" repair below.
8. If multiple connector wires are contaminated including the ground wires go to "Install new ABS Connector/Repair Harness" repair and replace
entire connector, ground wire and splice all other harness wires.
INSTALL NEW ABS CONNECTOR GROUND LEADS
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LM Range
Rover/2005 > Electrical Library. Then enter "C0362"
into the search window. Click "Document Content"
and click on Search. Select Electrical Library and
view found Connector Details.
1. Disconnect the ABS modulator ground eyelet at C0362. (Figure 1)
2. Release two clips and remove the top cover from the ABS connector. (left-hand clip arrowed Figure 2)
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3. Slide back the two locking tabs, one at each end of the connector (arrowed Figure 3).
4. Remove the tape covering the ground lead back to the eyelet.
5. Release the cavity 5 securing tab using the tool from the harness repair kit and remove the brown wire (2.5 mm) from cavity 5. (Figure 4 and
Figure 5)
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6. Release the cavity 1 securing tab using the tool from the harness repair kit and remove the brown wire (4 mm) from cavity 1. (Figure 6)
7. Remove the two ground wires from the harness.
8. Position the new ground wires to the harness.
9. Install the 4 mm wire into cavity 1 and the 2.5 mm wire into cavity 5.
10. Slide back the two connector end locking tabs. (Figure 7)
11. Wrap the exposed harness wires with new electrical tape. (Figure 8)
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12. Install the connector top cover.
13. Connect the ground eyelet at C0362 and tighten to 7-9 Nm (5-7 lbf.ft).
14. Install the connector onto the ABS modulator.
15. Install the battery ground cable.
16. Using T4, clear any stored fault codes.
17. Verify that the ABS/HDC warning light is no longer illuminated.
INSTALL NEW ABS CONNECTOR/REPAIR HARNESS
NOTE.
This procedure is required only if evidence exists of corrosion on multiple connector terminals. A repair kit is available which includes a
replacement ABS modulator connector with a short wiring harness section. In cases where multiple terminal corrosion is evident, also check for
corrosion of the modulator terminals and clean or renew if necessary.
1. Disconnect the ABS modulator ground eyelet.
2. Release the two clips and remove the top cover of the modulator connector. (Left-hand clip indicated in illustration in Figure 2)
3. Slide back the two locking tabs, one at each end of the connector (Figure 3).
4. Remove the harness tape from the ABS harness 100 mm (4 inches) past the ground wire breakout point to expose the individual wires of the
harness.
CAUTION:
The ground wire assembly is part of the new connector repair harness. No splice is required to install the ground wires to the ground location.
5. Overlay the new harness repair section (YMQ500292) onto the vehicle ABS harness to gauge the overall installation length.
CAUTION:
The wire color selected on the new harness section and vehicle harness
MUST match exactly for each splice.
CAUTION:
Splices should be staggered over about 200 mm (8 inches) [100 mm before the ground wire breakout ground point, and 100 mm past the ground
wire breakout point] to avoid bundling the connectors in one place.
6. Select matching wires from the vehicle harness and the repair harness and perform the following:
^ Cut the selected wire from the vehicle harness at a point permitting splicing to the selected repair wire.
^ If required trim the length of the wire from the repair harness.
^ Remove 4 mm (3/16 in) of wire insulation on both the vehicle harness wire and the repair wire to expose the conductor.
^ Join the matched wires, using the crimp joints and crimping tool from the Land Rover harness repair kit.
7. Repeat step 6 one wire at a time for all of the remaining un-spliced wires except the brown ground wires connected to the sealed eyelet.
8. Discard the connector removed from the vehicle harness.
9. Fully wrap the vehicle wiring harness using suitable wiring repair tape, covering the new crimped joints but ensuring that the ground lead is
left free for 100 mm (4 inches) outside of the wrap.
10. Connect the ground eyelet and tighten to 7-9Nm (5-7lbf.ft).
11. Secure the connector to the ABS modulator.
12. Connect the battery ground lead.
13. Using T4, clear any stored fault codes.
14. Verify that the ABS/HDC warning light is no longer illuminated.
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Disclaimer
Land Rover Range Rover Technical Service Bulletin # H387 Date: 001208
Campaign - Brake Fluid reservoir Cap Replacement
No: H387
Ref:
Issue: 1
Date: 12/08/00
SERVICE ACTION
Fluid Reservoir Cap - New Part Introduction
AFFECTED VEHICLE RANGE:
Range Rover (LP) All up to YA428098
SITUATION:
INCORRECT FILLING OF BRAKE FLUID RESERVOIR
There is a potential for the addition of fluids other than brake fluid to the brake system reservoir during normal maintenance. The filler cap installed
up to VIN YA428098 lacks the distinguishing characteristics to ensure that only brake fluid is added to the reservoir.
RESOLUTION:
INTRODUCTION OF HIGH VISIBILITY CAP
To help eliminate the potential for the addition of fluids other than brake fluid to the brake system reservoir during maintenance, a new reservoir cap
has been introduced. The cap is visually different in both appearance and color. The new cap is yellow with embossed lettering in black, identifying
that brake fluid only is to be installed in this reservoir.
At the next available service opportunity fit the new reservoir cap. All used vehicles in retailer inventory must have the new cap fitted prior to retail
sale.
PARTS INFORMATION:
SJL105210K Brake fluid reservoir cap Qty 1
LRN0002LABEL Campaign Label Qty 1 (Order quantity 1=100)
WARRANTY CLAIMS:
H387 Time 0.20 hrs.
Install yellow brake reservoir cap and campaign label Material allowance for campaign label $0.50
Normal warranty policy and procedures apply
REPAIR PROCEDURE
1. Remove old reservoir cap and discard.
CAUTION:
Care must be taken to avoid over-tightening the cap during installation.
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2. Fit the new YELLOW cap (SJL105210K) and tighten hand tight. (Figure 1)
CAMPAIGN LABEL INSTALLATION
NOTE:
Campaign labels may have multiple Campaign numbers written on them if multiple campaigns are performed at the same time.
1. Obtain a label (LRN0002LABEL) and prepare as follows:
a) Place the label on a hard surface.
b) Use a ballpoint pen and neatly write in the bare aluminum areas of the label the following information:
^ Campaign code "H387"
^ Your retailer code
^ Date of repair
CAUTION:
Do not touch the exposed label adhesive with your fingers. The bond will be diminished if contaminated prior to application.
3. Clean all grease and dirt from the radiator support member in the area shown.
4. Peel the completed campaign label from the backing paper and position it on the cleaned area of the cross member.
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5. Roll the label with the special roller tool to ensure that the adhesive makes continuous contact with the cross member surface.
Land Rover Range Rover Technical Service Bulletin # NHTSA00V187000 Date: 000628
Recall 00V187000: Brake Caliper Bolts Loose
Vehicle Description: Sport utility vehicles. One or both of the bolts that
retain the brake caliper to the axle may have missed a final assembly torque operation. Consequently they may be loose or possibly missing.
Caliper disengagement from the axle could result causing reduced vehicle
stability when braking and possibly locking up of the affected wheel.
Dealers will inspect these vehicles to verify that the proper torque has been applied.
Owner notification is expected to begin during July 2000. Owners who take
their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact
Land Rover at 1-800-637-6837. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT
(1-888-327-4236).Land Rover Range Rover Technical Service Bulletin # D333 Date: 000711
Recall - Brake Caliper Bolt Inspection
No: D333
Ref:
Issue: 1
Date: 07/11/00
RECALL
Incorrectly Tightened Caliper Bolts
AFFECTED VEHICLE RANGE:
Range Rover (LP) YA441000 to YA444043
SITUATION:
CALIPER RETENTION BOLTS INCORRECTLY TIGHTENED
Land Rover has determined that some vehicles built within the affected VIN range may have had incorrect torque applied to the caliper mounting
bolts. It is possible that incorrectly tightened bolts could loosen, placing the effectiveness of the braking system in jeopardy.
RESOLUTION:
TIGHTEN ALL BRAKE CALIPER RETENTION BOLTS
Determine if the vehicle has been inspected previously by accessing the Land Rover Link On-line DCS. If inspection is required, apply the specified
torque outlined in the Repair Procedure section of this TIB to ensure that all calipers on vehicles in the affected VIN range are securely fastened.
All affected vehicles currently held in Retailer inventory as new or used vehicles must be repaired prior to sale. Refer to Service Bulletin SRE00-03
for a listing of affected vehicles believed to be in Retailer inventory.
PARTS INFORMATION:
No parts involved
WARRANTY CLAIMS:
D333 Range Rover Time 0.35hrs
Confirm proper torque on all caliper mounting bolts (Material allowance for label included in time)
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 Land Rover Link Online DCS. 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
1. Raise vehicle on a lift, align the wheels straight ahead and set the parking brake.
2. Inspect all bolt locations to ensure that all bolts are resent.
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CAUTION:
A suitable extension will be required to access the caliper retention bolts. Flexible extensions should NOT be used.
3. Set torque wrench to 100 Nm (74 lbf.ft.).
4. Using a 12-point 13mm socket, tighten the left and right rear caliper mounting bolts (4 bolts total) to 100 Nm. (Figure 1)
5. Set torque wrench to 165 Nm (122 lbf.ft.).
6. Using 12 point 19mm socket, tighten the left and right front caliper mounting bolts (4 bolts total) to 165 Nm. (Figure 2)
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:
^ Service Campaign code performed ("D333")
^ Your Retailer code
^ The date of repair
2. Peel the label back, apply to radiator support and roll the label with the special roller.
Land Rover Range Rover Technical Service Bulletin # TEC700404 Date: 040820
Brakes - Front Brake Pad Wear Sensor Service Precautions
No: 70/04/04/NAS
Ref:
Issue: 1
Date: 20 August 2004
Pad Wear Sensor Damage
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AFFECTED VEHICLE RANGE:
New Range Rover (LM)
All
SITUATION:
BRAKE PAD WEAR SENSOR DAMAGED DURING REPAIRS
Incorrect methods used to remove the front brake pad wear sensor from the brake calliper during repairs can lead to sensor failure. The failure is
characterized by a fracture through the body of the front brake pad wear sensor. The cause of failure is generally the result of removal of the wear
sensor from the brake calliper by using a screwdriver or levering device.
RESOLUTION:
REMOVE SENSOR WITHOUT USING TOOLS
The front brake pad wear sensor MUST only be removed by hand. Move the front brake pad wear sensor from left-to-right and then up-and-down
repeating the motion until the sensor can be withdrawn from the brake calliper.
PARTS INFORMATION:
Information Only
DDW WARRANTY CLAIMS:
Information Only
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.Land Rover Range Rover Technical Service Bulletin # TEC860100 Date: 000303
Battery - Dead/Fails to Maintain A Charge
No: 86/01/00/NAS
Ref:
Issue: 1
Date: 03/03/00
Quiescent Current Draw
AFFECTED VEHICLE RANGE:
All Vehicles
SITUATION:
BATTERY IS DEAD OR FAILS TO MAINTAIN CHARGE
NOTE:
"Quiescent current" is current drawn from the battery by vehicle components that require power when the key is in the "off" position. The draw
may include the radio, clock, security system and ECU memory. It will also vary depending on the "sleep" status of various ECUs.
Some electronics, including plips from other vehicles in the vicinity, can "awaken" an ECU. When testing avoid the use of plips in the vicinity. If
consistently and repeatedly "awakened" over an extended time, the ECU quiescent draw can drain a battery.
A battery will self discharge at a rate between 0.1 - 1% at 20°C (68°F) depending on the age and condition of the battery. The self discharge rate will
INCREASE 1% for every 10°C (19°F) increase in temperature
Dirt and moisture on the top surface of the battery will also increase the discharge rate.
A quiescent current draw that exceeds specification can cause excessive battery drain while the engine is off. This may result in a dead battery or
inability of the battery to maintain a charge.
RESOLUTION:
TEST VEHICLE FOR EXCESSIVE QUIESCENT CURRENT DRAW
When a vehicle exhibits the above symptoms, measure the current from the battery after all vehicle systems have been shut down. Verify that the
current is less than or equal to the specified current level for that vehicle in the Repair Procedure section of this TIB.
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PARTS INFORMATION:
No parts are necessary.
WARRANTY CLAIMS:
86.60.89126 Time 0.40 hrs.
Measure quiescent current draw from battery
FAULT CODE: T
Normal warranty policy and procedures apply
REPAIR PROCEDURE
MEASURE QUIESCENT CURRENT LEVEL
1. Verify that the battery is fully charged.
2. Remove key from ignition lock.
3. Open hood.
4. Disconnect bonnet switch.
5. Close all doors.
6. Verify that all interior lights have extinguished.
7. Lock vehicle with remote.
NOTE:
Ensure that the vehicle electrical system remains powered throughout the following steps.
8. Connect a suitable ammeter between the battery and vehicle electrical system.
9. Wait 30 minutes for all on-board systems to power down. In some cases a Discovery Series II may take up to 60 minutes to completely power
down.
NOTE:
Any accessories fitted to the vehicle with a permanent battery connection, will adversely affect quiescent current. They should be
disconnected before testing the vehicle
10. Measure the current level between the battery and vehicle electrical system.
11. Verify that the current levels recorded are less than those specified for that vehicle in the table.
12. If current levels exceed those specified in the above table, it is necessary to evaluate each electrical subsystem to locate the source of the
excessive current draw.
Land Rover Range Rover Technical Service Bulletin # TEC861203 Date: 031031
Cooling System - Coolant Leak From Bleed Tube
No: 86/12/03/NAS
Ref:
Issue: 1
Date: 10/31/03
Battery Gases Impact Surrounding Tubing
87
AFFECTED VEHICLE RANGE:
Range Rover (LP) All
SITUATION:
COOLANT LEAK FROM BLEED TUBE
A coolant leak can develop from the coolant bleed tube as the result of deterioration caused by vented battery vapors.
RESOLUTION:
INSTALL BATTERY VENT PIPE AND BLEED TUBE
When the source of the leak is determined to be the coolant bleed tube between the expansion tank and the radiator, install the battery vent pipe and
a new bleed tube as outlined in this TIB.
PARTS INFORMATION:
PCH000280 Bleed Tube Assembly Qty 1
YTJ500010 Battery Vent Kit Qty 1
AS400 WARRANTY CLAIMS:
86.15.89/39 Time 0.20 hrs.
Install new battery vent kit
FAULT CODE: A
26.30.37 Time 0.10 hrs.
Install new expansion tank to radiator bleed tube
(claim as a separate process)
FAULT CODE: F
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
REPAIR RADIATOR TO EXPANSION TANK COOLANT BLEED TUBE
1. Open the hood.
2. Place a container under the front of vehicle to catch any coolant spillage.
3. Release the two clamps at either end of the coolant bleed tube connecting the expansion tank and the radiator.
4. Release the coolant bleed tubing from two locating clips on the inner fender.
5. Disconnect the ends of the coolant bleed tube and remove it from the vehicle.
6. Remove the original coolant bleed tube clamps (ESR2222) and install them onto the new coolant bleed tube.
7. Fit the new coolant bleed tube to the radiator and the expansion tank.
8. Secure the new tubing with the pre-positioned reused clamps.
9. Secure the coolant bleed tube into the locating clips on the inner fender
88
10. Check and if necessary top up the cooling system.
INSTALL BATTERY VENT PIPE KIT
CAUTION:
The battery and the charging system must be operating correctly to ensure the corrective actions in this bulletin are effective.
1. Evaluate the battery and the charging system and ensure the charging system is operating correctly.
2. Remove the blanking plug from the inner fender, adjacent to the battery. (Arrowed in Figure 1)
NOTE:
The vent pipe kit will have to be connected to either the front or side of the battery depending on the type of battery installed. (Inset in
Figure 2 or Figure 3)
3. Connect the new vent pipe to the battery breather outlet.
4. Drill a 10 mm hole in the center of the blanking plug. (Arrowed in Figure 4).
5. Insert approximately 60 mm (2 inches) of the vent pipe through the hole in the blanking plug.
6. Route the vent pipe along the newly installed coolant bleed tube and position the blanking plug next to its location in the inner fender.
7. Determine the amount of vent pipe required for the installation and adjust the initially inserted length of pipe as required to avoid excess vent
piping in the engine compartment.
8. When the correct length has been determined, cut the vent pipe at approximately 30 mm (1-1/4 inch) beyond the grommet. (Figure 4).
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9. Insert the vent pipe through the inner fender and install the blanking plug in the inner fender opening from which it was removed. (Figure 5)
10. Secure the vent pipe to the coolant bleed tubing with a tie strap. (Figure 6)
11. Ensure the battery cover is properly positioned and secure and that all hoses and wires are properly routed.
12. Close the hood.
Land Rover Range Rover Technical Service Bulletin # TEC860502 Date: 020809
Electrical - Intermittent Electrical/No Start Problems
No: 86/05/02/NAS
Ref:
Issue: 1
Date: 08/09/02
Battery Clamp Bolt Availability
AFFECTED VEHICLE RANGE:
Range Rover (LP) All
Discovery (U) All
Discovery (LT) All
Freelander (LN) All
SITUATION:
BATTERY CLAMP BOLT MAY SHEAR
The customer may complain of non-starting or intermittent electrical problems. The root cause of these symptoms may be a broken battery clamp
bolt on either the positive or negative cable clamp.
RESOLUTION:
REPLACEMENT BOLT AVAILABILITY SIMPLIFIES REPAIR
Land Rover has made available the clamp bolt and nut as separate parts to avoid the necessity of replacing the entire wiring harness should a bolt
fracture.
PARTS INFORMATION:
YTJ000010 Battery clamp nut and bolt assembly Qty 1 per clamp
WARRANTY CLAIMS:
86.15.89/34 Range Rover, Discovery Series II Time 0.10 hrs
Freelander Time 0.05 hrs.
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Install replacement battery clamp bolt
FAULT CODE: D
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
REPLACE DAMAGED BOLT
CAUTION:
Always remove the negative cable first when disconnecting a battery. Refer to the WSM and observe all cautions and warnings.
1. Disconnect battery and extract damaged bolt.
2. Install new bolt and nut (YTJ000010) detailed in parts information.
3. Tighten the new bolt to between 4 and 6 Nm (35.5 - 53 lbf.in.) on all vehicles.
Land Rover Range Rover Technical Service Bulletin # TB0100 Date: 001110
Engine Controls - Bosch ECM Reprogramming
No: TB/O1/00/NAS
Ref:
Issue: 1
Date: 11/10/00
Bosch Engine Management ECM Programming
AFFECTED VEHICLE RANGE:
Range Rover (LP) All with Bosch EMS
Discovery Series II (LT) All with Bosch EMS
ALLDATA Editors Note:
Requires proprietary software. See dealer for information.
SITUATION:
CURRENT ORDER PROCESS FOR PROGRAMMING BOSCH ECM
For the past few months, the procedure for replacing a Bosch Engine Management ECM has been cumbersome. All requests for ECM replacements
have been channeled through the Technical HelpLine because local programming of the ECM was not possible.
RESOLUTION:
TESTBOOK PROGRAMMING OF ECM
NOTE:
Proper diagnostics are vital to ensure understanding of the problem. The ECM is probably the least likely component in the system to fail.
91
With the latest release of TestBook disk DRG0011,the above process is no longer necessary. It is now possible to order ECM's following normal
parts ordering procedures and to program them at the Retailer using TestBook.
PARTS INFORMATION
WARRANTY CLAIMS
REPAIR PROCEDURE
DIAGNOSIS AND REPLACEMENT OF BOSCH ECM.
NOTE:
This repair procedure must have prior approval from the Technical HelpLine.
1. Consult with the Technical HelpLine for authorization.
2. Disconnect battery ground cable.
3. Verify ignition switch is in the "O" off position.
4. Remove defective Bosch ECM from the vehicle.
5. Verify that the replacement unit has the same part number as the removed unit.
6. Install new Bosch ECM to vehicle.
7. Connect battery ground cable.
8. Connect TestBook and insert disk DRG0011 or later.
9. Turn ignition switch to "II" position.
10. Select Diagnostics in TestBook.
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NOTE:
Selecting "Petrol Engine Diagnostics" (Figure 1) will bring up screen labeled "DDQA0001 PARTCOMMS". TestBook will tell you that
"This ECM is in partial comms mode".
11. Select "Petrol Engine Diagnostics".
12. When the message "This ECM is in partial comms mode". Appears, select "PROGRAM" in the bottom corner of the screen.
13. Press "CONTINUE" at next screen labeled "DDQA7100 STARTNODE"
NOTE:
TestBook will now display the VIN numbers stored for the BCU, SRS ECU and ABS ECU.
14. Select "CONTINUE" after ECU VIN display.
CAUTION:
At this point TestBook may come to a "FAILEDINIT" screen. If asked whether you want to replace hardware, always select "NO". If
necessary, cycle ignition here as prompted by TestBook. You may have to press "RE-TEST" to regain communications with the Bosch
ECM.
15. When asked by TestBook whether you want to replace hardware, ALWAYS select "NO".
NOTE:
During programming, do not interrupt power to the ECM. Programming will take approximately 5 minutes.
16. Establish communications with the Bosch ECM. TestBook will display what tune it is about to download.
17. Press "Continue" to program the ECM.
18. After successfully programming ECM, re-synchronize the security immobilization using TestBook to start the vehicle.
Land Rover Range Rover Technical Service Bulletin # TEC0204 Date: 040604
Engine Controls - ECM Tune Download Procedure
No: TB/02/04/NAS
Ref:
Issue: 1
Date: June 4, 2004
ECM Tune Download Procedure
AFFECTED VEHICLE RANGE:
Range Rover (LM) All
SITUATION:
CLARIFICATION OF TUNE DOWNLOAD PROCEDURE REQUIRED
93
A number of situations may require the reloading of the Engine Control Module (ECM) tune on Range Rover vehicles. Because there are several
areas of potential confusion in this process, it is possible for an incorrect procedure to be followed, disrupting the download and requiring multiple
attempts.
RESOLUTION:
FOLLOW CLARIFIED STEP-BY-STEP PROCEDURE
NOTE:
Whenever "compulsory" tunes are issued on a T4 disc, the T4 will initiate an automatic update process that the Technician should follow to its
conclusion. "Non-compulsory" tunes associated with certain service procedures will require the use of this TIB for guidance through the tune
installation process.
Review and follow the illustrated procedure in this TIB whenever a "non-compulsory" download of a new ECM tune is performed. The
Technician will need to follow these instructions to manually select the tune for download. Note the definition of the term "ASSEMBLY" in the
context of T4 on-screen instructions:
"ASSEMBLY" = INSTALLED ECM HARDWARE plus T4 DOWNLOADED SOFTWARE
PARTS INFORMATION:
No parts required
DDW WARRANTY CLAIMS:
Information Only
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
CLARIFICATION TO NEW RANGE ROVER ENGINE ECU TUNE UPDATE PROCESS
1. To program engine ECU insert disc "Range Rover 12" or later.
^ Begin a diagnostic session.
^ Click [vehicle configuration] from main menu.
^ Then on this screen select "EMS ECU checks".
94
2. Verify the battery voltage is fully charged (12 volts or greater).
NOTE:
The battery must be capable of maintaining full charge during this process which is expected to take 15 - 18 minutes total.
3. Connect a battery charger set on low amp current charge to maintain battery state during this process.
4. When the battery condition is satisfactory and the charger connected, click "Continue."
NOTE:
T4 will check the engine ECU for available programming records. If the ECU is full T4 will prompt for replacement.
5. Click "Continue."
NOTE:
This screen is NOT relevant for vehicles that only need the tune update.
95
6. Click "Continue.
NOTE:
This screen is NOT relevant for the update.
7. Click "NO"
NOTE:
An "ASSEMBLY" is defined as the combination of HARDWARE + SOFTWARE. By changing the TUNE the ASSEMBLY will also be
changed.
8. Click "YES."
NOTE:
If "View Fixes" is clicked, T4 will return to the previous screen.
96
9. Click "Confirm Fix" to continue.
NOTE:
This screen identifies which tune is being installed. Technical Information Bulletins or other documentation will list a specific "Assembly"
or software level which can be verified here. If the correct Assembly is not listed verify the following:
^ The correct diagnostic CD is being used to perform the tune update.
^ Other unexpected issues may have caused T4 to select the incorrect tune.
10. If you do not have the correct assembly number, contact Land Rover Technical Helpline.
11. If you get the proper assembly number click "Continue."
NOTE:
T4 will commence the ECU tune download. This screen will indicate the progress. The % download is indicated at the top of screen
indicating that the process is active and T4 has not locked up. When done AFTER approximately 15 minutes, the page will advance to a
"Download Complete" with some details displayed.
12. If there is an incomplete download, "Download Failed" will display. Follow the instructions displayed by T4 carefully to complete ECM
programming.
13. If the additional attempts fail repeatedly, there, may be an ECM or other mechanical vehicle issues. Investigate the vehicle for the problem.
14. To verify that the programming has been completed, go to the main T4 menu and select: System Diagnosis, Petrol Engine Management,
97
Vehicle Maintenance, Programming History.
Land Rover Range Rover Technical Service Bulletin # TA021701 Date: 021205
Emissions - Secondary Air Hose Tube Reassembly
TA02 1701
December 5, 2002
ATTENTION:
Service Manager
Service Advisor
Technician
V8 Vehicles with Secondary Air Injection
Discovery Series II and Range Rover 2000-2002
When performing engine-related repairs on a vehicle equipped with secondary air injection, the system pipes may need to be removed to facilitate
repairs. Warranty claims indicate that the these pipes are often being replaced unnecessarily.
Affected Components
^ Pipe secondary air injection
^ Adaptor SAI rail
Investigation shows that when the components are dismantled from the engine/vehicle without damage difficulty may be experienced when
reassembly of the removed pipe to the engine is attempted after repair. Exhaust heat from the engine has, over time, distorted the pipes very slightly.
Removal from the engine permits the pipes to move/expand to release the built-up stress.
The distortion makes it very difficult to quickly re-assembly the pipes back onto the adaptors without cross threading the union nuts fittings. Patience
and a little extra time are required. Refer to the RAVE WSM sections 17.25.17-18 and perform the following refined assembly process:
1. Carefully align the pipe and the pipe union nuts.
2. Start the pipe nuts by hand. (Figure 1)
CAUTION:
Damage to the fittings can occur if care is not exercised during the assembly process.
3. Tighten both union nuts completely finger tight BEFORE any tools are used.
4. Install air manifold bracket nuts and tighten.
5. Torque the pipe union nuts to 25 Nm (18 lbf.ft.)
Land Rover Range Rover Technical Service Bulletin # TEC760102 Date: 020222
Interior - Front Seat Fore/Aft Rocking
No: 76/01/02/NAS
Ref:
98
Issue: 1
Date: 02/22/02
Front Seat "Rock"
AFFECTED VEHICLE RANGE:
Range Rover (LP) XA410287 - 1A459560
SITUATION:
EXCESSIVE FREE PLAY IN FRONT SEAT
The customer complains of fore and aft "rocking" of the complete seat during acceleration or braking.
The condition can occur on either the LH or RH seat. Free play within the power operated seat height adjustment mechanism may be determined to
be the cause.
RESOLUTION:
REPLACE SEAT CUSHION MOTOR/GEARBOX ASSEMBLIES
Where a customer complaint of excessive seat movement is confirmed, replace the seat cushion height and tilt motor/gearbox assemblies.
PARTS INFORMATION:
HSB000010 Kit - memory seat motors Qty 1
^ NPN Roll pin Qty 2 included in kit
^ NPN Spring clip Qty 2 included in kit
WARRANTY CLAIMS:
78.70.89/34 Time 0.60 hrs.
Exchange seat assembly motors
FAULT CODE: G
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
REPLACE SEAT MOTORS
WARNING:
Refer to the WSM section covering SRS and observe the cautions and warnings there before removing the seat from the vehicle.
NOTE:
Before disconnecting the power supply to the seat, use the seat controls to raise the seat to its highest position and tilt fully forward.
1. Remove affected seat from the vehicle.
2. Refer to Workshop Manual section 78.70.29 and replace front seat tilt motor (Figure 1 "A").
3. Refer to Workshop Manual section 78.70.27 and replace the front seat rise-and-fall motor (Figure 1 "B").
4. Install the repaired seat and confirm proper seat operation.
99
Land Rover Range Rover Technical Service Bulletin # TEC861103 Date: 031031
Audio/Navigation Systems - Numerous Faults
No: 86/11/03/NAS
Ref:
Issue: 1
Date: 10/31/03
Audio and Navigation System Troubleshooting
AFFECTED VEHICLE RANGE:
New Range Rover (LM) See PROCESS for specific VIN breaks
Range Rover (LP) Equipped with NAV
SITUATION:
CUSTOMER COMPLAINTS REGARDING AUDIO AND NAV OPERATION
NOTE:
From VIN 3A128030 a new radio was introduced on 2003 Range Rover. This radio has new software installed that eliminates many of the issues
addressed in this TIB
A customer may complain about a range of symptoms in the navigation and audio system of the New Range Rover. Customers with Range Rover
(LP) vehicles may in some cases experience similar navigation system faults.
RESOLUTION:
TROUBLESHOOT THE FAULTS AND RESOLVE
Using the procedures in this TIB the following 2003 Range Rover audio and navigation complaints can be addressed:
^ Radio retunes itself to 87.7 at start-up
^ Navigation voice commands may sound distorted, or crackly and navigation system distance units appear in Miles/Yards rather than
Miles/Feet
^ Navigation audio volume too low
^ Adjustment of speed dependent volume
^ Radio display mode "disappears"
PARTS INFORMATION:
As indicated by diagnosis
AS400 WARRANTY CLAIMS:
NOTE:
Process 2 units of measure adjustment and processes 3 through 5 are customer-request adjustments. The procedures are presented for
INFORMATION ONLY
86.90.65 Time 0.40 hrs
Procedure 1 Personalization - Switch off "Radio Key Memory" feature
86.90.64/01 Time 0.20 hrs
Procedure 2 Additional Test - Install "JAMES" voice to
resolve distortion concerns ONLY
FAULT CODE A
DDW WARRANTY CLAIMS:
100
NOTE:
Process 2 units of measure adjustment and processes 3 through 5 are customer-request adjustments. The procedures are presented for
INFORMATION ONLY
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
NOTE:
A new radio was introduced on 2003 Range Rover from VIN 3A128030. This radio has new software installed, which increases the range of
adjustment of the navigation audio volume. The new radio also includes the personalization feature "radio key memory".
^ If TestBook/T4 disk DJL0D07 or later is used to communicate with the vehicle, there should not be error messages from the radio during
vehicle personalization.
^ If an older TestBook/T4 disk is used, error messages such as "the ECU configuration failed the following ECU: radio. The ECU has an
obsolete coding index and must be renewed". The message indicates that during programming, the communication failed on the radio.
^ The new radio is configured correctly from the factory and therefore does not require personalization. This message can be ignored.
PROCESS 1: PLACE "RADIO KEY MEMORY" FEATURE TO OFF SYMPTOM Radio auto-tunes to "87.7"
NOTE:
The "radio key memory" feature is not supported on early radios. If the option is enabled on these vehicles it will lead to the 87.7 tune problem.
1. If a customer complaint of "87.7" retuning at starting the car in the morning is confirmed, reprogram and disable the "radio key memory"
feature as follows:
^ Connect TestBook/T4 to the vehicle.
^ Start the engine and turn on the headlights.
NOTE:
In the next step ignore Dimmer Potentiometer, and Xenon Headlamp LH and RH below 7.5V unless there is a problem with these systems.
^ Clear fault codes in vehicle ECU's.
^ Select "Vehicle Configuration" and then select "Personalization".
^ Go to the "Radio Key Memory" line item and switch it ON".
NOTE:
The saving of the settings in the next step will take a few minutes.
^ Press the "Continue" button to save the settings to the vehicle and wait for TestBook/T4 to complete the task.
^ Exit out of the testbook screens to the main screen.
^ Disconnect TestBook/T4 lead from the vehicle, and switch off the vehicle ignition.
^ Remove the key and wait one minute.
^ Connect TestBook/T4 to the vehicle.
^ Start the engine and turn on the headlights.
^ Select "Vehicle Configuration" then select "Personalization".
^ Go to the "Radio Key Memory" line item and switch it OFF.
101
^ Press the "Continue" button to save the settings a second time. This time the radio key memory feature is disabled.
^ Fully exit TestBook/T4 to the main screen, turn off lights and engine.
PROCESS 2: CORRECT NAVIGATION VOICE/DISTANCE SELECTION TO "JAMES"
CAUTION:
Installation of a new navigation computer requires programming the new unit to the vehicle. Connect TestBook/T4 and select Diagnostics,
Vehicle Information Systems, Vehicle Maintenance. Perform the ECU renewal procedure as you would on any other ECU on this vehicle. If you
do not program the navigation computer in this way, it does not "learn" the vehicle specification or market.
CAUTION:
Two languages can be loaded into the navigation system at any time. The recommended navigation system voices for the US are "James" and
"Spanish Female". The recommended navigation system voices for Canada are "James" and "French Female". You should never select both the
Male AND Female selection of each language. I.e. never select "US English Male" and "US English Female" together as the system will not
function correctly.
NOTE:
Land Rover has discovered a software bug when using the "UK English Male" voice option on the New Range Rover navigation system. The use
of the "James" voice will give the same accent, but uses US terminology (for example: Freeway/Circle instead of Motorway/Roundabout) and
James does not suffer from the distorted or clipped speech pattern. For detailed instructions on changing navigation languages see the Retailer
PDI/personalization process on the InfoTrail
SYMPTOM Commands sound distorted, or crackly.
1. If the navigation system "peaks" with a distorted voice or the ends of sentences are clipped or cutoff, change the voice in the navigation system
to "James".
NOTE:
The change of units of measure is a customer requested adjustment. It is not a fault.
SYMPTOM Navigation system distance units appear in miles/yards rather than miles/feet
2. If the navigation system states distance in Miles/Yards rather than the normal Miles/Feet, set the navigation voice to "James". The distance
units will automatically change to Miles/Feet.
PROCESS 3: CORRECT AUDIO VOLUME COMPLAINT
SYMPTOM Navigation audio volume too low on 2003 Range Rover up to 3A128030
1. If the navigation system volume is too low set radio audio systems for optimal performance as follows:
^ Press the left rotary knob to turn the radio on.
^ Press the "INFO" button.
^ Select "NAV-MIN" and use right rotary control to highlight "NAV-MIN+".
^ Press right rotary control as many times as necessary to obtain a setting of "+9"
2. Set navigation system for optimal performance as follows:
NOTE:
Setting volume to +10 or +12 will mute the radio entirely during a navigation audio command. Setting volume to +8 will give maximum
navigation volume, but will mix the navigation and radio audio during a navigation voice command.
^ Press the "MENU" button on the MFD.
^ Select "On Road Navigation" and then "Information".
^ Select "Volume Navigation".
^ Set navigation volume to "+8".
NOTE:
The latest radio variant increases the range of adjustment of the navigation system voice commands volume significantly.
PROCESS 4: ADJUSTING SPEED DEPENDENT VOLUME ON 2003 RANGE ROVER
102
SYMPTOM Speed dependent volume too high or too low
NOTE:
"GAL" is an acronym derived from German representing "Speed Dependent Volume." A GAL setting of "1"is less sensitive and will increase the
radio volume proportionally less as vehicle speed increases. A GAL setting of 6 is the most sensitive and will increase the volume the most. The
factory setting is "2".
1. If the volume change is either too great or not enough when the vehicle speed changes, perform the following adjustment procedure to increase
or decrease the sensitivity:
^ Verify that the power LED next to left rotary knob is NOT illuminated (the radio is off).
^ Press the left rotary knob to energize the radio.
^ Press and hold the "SELECT" button until the service mode is displayed.
^ Press and hold the "<>" button until the "GAL" display is visible.
^ Press the desired numbered button "1" through "6" to alter the GAL setting. Press the left rotary knob to turn off the radio.
PROCESS 5: RADIO DISPLAY MODE SELECTION
SYMPTOM: After a radio station is selected the Radio screen display disappears.
1. If the customer desires the radio screen display to remain revealed after station selection, the following steps will retain the display:
^ Press the left rotary knob to energize the radio.
^ Select the station of choice by search or by preset button
^ Press the RH side of the "MODE" rocker switch in the lower left of the Multi-Function Display panel.
NOTE:
The screen will toggle between the radio display and the menu screen.
^ Select the desired screen by pressing the MODE display symbol as required.
Land Rover Range Rover Technical Service Bulletin # TEC860703 Date: 030613
Audio System - Radio AM Band Tunes Incorrectly
No: 86/07/03/CAN
Ref:
Issue: 1
Date: 06/13/03
Poor AM Radio Reception - Canadian Vehicles
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
SITUATION:
RADIO TUNES INCORRECTLY
The AM frequency is +1kHz out of range for the Canadian market.
RESOLUTION:
103
CODE RADIO TO "USA" SPECIFICATION
Upon customer compliant of the above condition or at Vehicle Preparation for Delivery, coding the radio to the USA setting will resolve the
situation. Where a complaint of the above is confirmed, follow the procedure below to access the radio's service menu and change the programmed
area from Canada to USA.
PARTS INFORMATION:
No Parts
WARRANTY CLAIMS:
86.50.89/36 Time is 0.10 hrs.
Correct AM Radio tune program
FAULT CODE: A
Normal warranty policy and procedures apply. Material allowance is included in labor operation.
REPAIR PROCEDURE
SELECT "USA" SETTINGS
NOTE:
This procedure will also have to be carried out after setting or confirming the market configuration with TestBook/T4.
1. Press the LH button to turn on the radio / multi-function display (MFD) ("A" in Figure 1).
2. Press and hold the Select button ("B" in Figure 1) until the serial number is displayed on the MFD.
3. Press the scroll / seek button ("C" in Figure 1) until area CANADA is displayed.
4. Press 1 ("D" in Figure 1) and set the area to USA.
5. Turn the radio off, then on and check the AM radio reception.Land Rover Range Rover Technical Service Bulletin # TA001201 Date: 000216
Engine - Excessively High/Low Oil Dipstick Readings
TA00 1201
February 16, 2000
ATTENTION:
Service Manager
Service Advisor
Technician
Incorrect Dipsticks Fitted
AFFECTED VEHICLES:
Discovery Series II (LT) Up to YA261798
104
Range Rover (LP) Up to YA435869
SITUATION:
On non-LEV engines, oil level reads very high above full indicator mark on dipstick
OR
On LEV engines, oil level is very low or no oil is indicated on the dipstick.
These readings are most likely the result of the incorrect specification dipstick being fitted to the engines. Prior to the above safe VINs the following
conditions may be encountered.
^ LEV engines with non-LEV dipsticks (ERR4905)
^ Non-LEV engines with LEV dipsticks (LQM1OO92O)
RESOLUTION:
At PDI, verify oil level following normal procedures.
^ If a reading that is too high or too low is encountered, inspect the end of the dipstick for a plastic tip and measure the length of the dipstick to
verify that the correct dipstick is fitted to the vehicle.
^ If it is determined that the dipstick is the wrong specification, install the correct part number from swap stock if available or using a new part.
PARTS INFORMATION:
NOTE:
Retailers should retain any dipsticks swapped out of vehicles for potential use in a second vehicle with the opposite problem. There is nothing
wrong with the dipstick, it is just fitted to the incorrect engine family.Land Rover Range Rover Technical Service Bulletin # TEC860400 Date: 010727
Starter - Engine No-Start Condition
No: 86/04/00/NAS
*Ref: 86/08/01/NAS
Issue: 2
Date: 07/27/01*
Loose Starter Cable Connection
AFFECTED VEHICLE RANGE:
Range Rover (LP) Bosch-Starter Equipped
Discovery Series II (LT) ALL
Discovery (U) Bosch-Starter Equipped
* indicates updated information
SITUATION:
LOOSE ELECTRICAL CONNECTOR AT STARTER MOTOR
Vehicles equipped with a Bosch starter may experience non-start symptoms that suggest that the starter motor is not functioning correctly. These
vehicles may fail to crank or intermittently may fail to crank.
The primary electrical connection between the starter and the battery may not be adequately tightened on vehicles exhibiting these symptoms. A low
torque condition will not provide a solid electrical connection.
RESOLUTION:
105
TIGHTEN CABLE CONNECTION TO SPECIFICATION
Whenever a no-crank situation is encountered on Range Rover or Discovery vehicles equipped with a
Bosch starter, the first check should be to tighten the main starter electrical cable connection to the
specified torque.
PARTS INFORMATION:
Locally Sourced
^ Star lock washer Qty 1
WARRANTY CLAIMS:
NOTE:
The procedure in this TIB should always be performed before replacing a starter to eliminate the possibility that an improperly tightened
solenoid nut is not the root cause of the no-crank problem.
86.60.89/27 Time 0.20 hrs.
Install star type lock washer and tighten starter cable to specified torque
FAULT CODE: S
Normal warranty policy and procedures apply
REPAIR PROCEDURE
TIGHTEN STARTER SOLENOID NUT
NOTE:
Replacement of the starter motor is not indicated unless the electrical connection has been checked for proper torque as described below.
1. Disconnect battery ground terminal.
2. Slacken and remove the battery-lead-to-starter-solenoid securing nut at the starter solenoid.
3. Clean all connection surfaces.
4. Install a star washer on the solenoid stud.
5. Install and tighten the nut to 18 Nm (13 lbf.in.). (Figure 1)
6. Clean and install battery ground terminal.
7. Start vehicle to verify repair.
NOTE:
If vehicle fails to crank after the torque repair, replacement of the starter motor may be indicated following standard Workshop Manual
and Warranty procedures provided:
^ Current supply to the starter terminal is normal (12 Vdc).
106
^ Other systems are functioning normally.
*NOTE:
New drive plate balance weights should be fitted whenever a starter motor is replaced on vehicles within the following VIN ranges:
Discovery Series II (LT) XA900012 to XA907212
XA200412 to 1A299999
1A700000 to 1A729921
Range Rover 4.0146 (LP) XA410483 to 1A459035
Always perform the procedures in TIB 86/08/01/NAS when the starter requires replacement. Inspect pinion and over-run clutch for evidence of
contact or "machining" damage to components. If damage is evident, balance weight replacement is required to remove the source of the damage.*
Land Rover Range Rover Technical Service Bulletin # TEC860801 Date: 010727
Starter - Knocking Noise When Starting Engine
No: 86/08/01/NAS
Ref:
Issue: 1
Date: 07/27/01
Knocking Noise When Starting
AFFECTED VEHICLE RANGE:
Discovery Series II (LT) XA900012 to XA907212
XA200412 to 1A299999
1A700000 to 1A729921
Range Rover 4.0/4.6 (LP) XA410483 to 1A459035
SITUATION:
KNOCKING SOUND WHILE STARTER OPERATING, OR STARTER FAILURE
The customer may complain that a knocking noise is heard when the starter motor is activated. The noise will go away when the engine starts and the
starter disengages. The starter pinion may be coming in contact with original style drive plate balance weights.
RESOLUTION:
INSTALL NEW DRIVE PLATE BALANCE WEIGHTS
New configuration drive plate balance weights have been developed to eliminate the potential contact with the starter during engagement. The new
weights should be installed when a customer complaint is confirmed and whenever a new starter is installed on vehicles within the affected VIN
range.
PARTS INFORMATION:
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NOTE:
The new 9.5 gram weight replaces the original 9.5 gram and 9.7 gram weights, (Refer to items 4 and 5 on Attachment 1).
LBB000550 Kit, Balance Weights (See Attachment 1)
^ 3.3gram Qty 2
^ 4.3gram Qty 2
^ 6.4gram Qty 2
^ 9.5gram Qty 1
WARRANTY CLAIMS:
12.53.89/41 Time 0.55 hrs.
Install replacement drive plate balance weights
FAULT CODE: K
Use applicable starter motor replacement operation number if required.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
108
REPAIR PROCEDURE
INSTALL NEW SPECIFICATION DRIVE PLATE BALANCE WEIGHTS
NOTE:
The new weights should be fitted whenever a starter motor is replaced. Always perform the procedures in TIB 86/04/00/NAS before replacing a
starter motor for a "no-crank/no-start" symptom. If the starter requires replacement, inspect pinion and over-run clutch for evidence of contact or
"machining" damage to components. If damage is evident, balance weight replacement is required to remove the source of the damage.
1. Confirm customer complaint of noise when cranking.
2. Disconnect the battery earth lead.
3. Raise the vehicle.
4. Identify the two rubber access plugs fitted to the rear flange of the engine oil sump.
NOTE:
Determining the best rubber plug to remove is a vehicle-dependant technician choice.
5. Select and remove the most convenient plug for access.
CAUTION:
Any weights dropped into the power unit must be retrieved via the access plate on the gearbox.
6. Replace the drive plate balance weights with the low profile balance weights from kit (LBB000550) as follows:
^ Rotate the drive plate until a weight becomes visible through the plug opening.
^ Carefully remove that weight using an Allen wrench.
^ Select a new balance weight from the kit, of equivalent mass to the original removed weight.
^ Fit the new weight to the drive plate in the same location as the removed weight.
^ Tighten weight securing Allen screw to 10 Nm (88.5 lbf.in.).
CAUTION:
Refer to Attachment 1 for dimensional and visual identification of original weights and the equivalent mass new weights.
^ The replacement weight must always be fitted to the same hole from which the original weight was removed.
^ Always replace the weights on a ONE FOR ONE BASIS to ensure that they are of the correct mass and fitted in their correct positions.
^ The new balance weight is designed so that it can only be fitted in one orientation.
7. Repeat the replacement process in step 6 until all weights have been replaced.
8. When all weights are in position and tightened, rotate the drive plate one complete revolution to confirm that all weights have been replaced.
9. Refit the rubber access plug to the rear flange.
10. Lower the vehicle and reconnect the battery ground cable.
11. Verify proper starter operation.
Land Rover Range Rover Technical Service Bulletin # TEC861603 Date: 031205
Instruments - Fuel Gauge Won't Rear FULL After Fill-Up
No: 86/16/03/NAS
Ref:
Issue: 1
Date: 12/05/03
Inaccurate Fuel Gauge Reading at "Full"
AFFECTED VEHICLE RANGE:
New Range Rover (LM) up to 4A154473
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NOTE:
A vehicle after the safe VIN 4A154473 that has had work performed using a TestBook/T4 disc before "Range Rover 10" may experience this
complaint also because older software can have been loaded.
Service Action B136 dealt with this issue for vehicles in Retailer inventory.
SITUATION:
FUEL GAUGE READS BELOW THE FULL MARK
The customer may complain that the fuel gauge does not indicate "full" when the vehicle has been filled with fuel. Vehicles within the above VIN
range may require a software update. An error within early instrument pack software causes an incorrect fuel gauge level reading when the fuel tank
is actually filled to capacity.
RESOLUTION:
PROGRAM INSTRUMENT PACK
Should a customer complain that the fuel gauge does not read correctly, re-configure the instrument pack following the procedure outlined below
using TestBook/T4 CD Range Rover 10.
PARTS INFORMATION:
None required
TOOL INFORMATION:
CAUTION:
Use only Range Rover TestBook/T4 disc version 10 or later to ensure that the fuel gauge calibration is set to have the gauge read to the full
mark. TestBook/T4 disc .."Range Rover 10" or later
AS400 WARRANTY CLAIMS (CANADA ONLY)
19.90.89/28 Time 0.30 hrs.
Re-configure Instrument pack
FAULT CODE: A
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
RE-CONFIGURE INSTRUMENT PACK USING TESTBOOK/T4
CAUTION:
Use only "Range Rover 10" TestBook/T4 disc or a later version to adjust the fuel gauge reading on an original instrument pack. This will ensure
that the fuel gauge calibration is set to have the gauge read to the full mark.
CAUTION:
Installation of a new "virgin" replacement Instrument Pack requires the use of the New Range Rover TestBook/T4 disc "DJL0D04" to initialize
the programming of the virgin Instrument Pack. The "Range Rover 10" disc can then be used to adjust the fuel gauge reading to the correct
configuration. Consult with the Technical HelpLine for assistance if required.
1. Connect TestBook/T4 to the vehicle and load disc Range Rover 10 or a later version.
2. Follow the on-screen instructions and select "Vehicle Configuration".
3. Follow the on-screen instructions and select "Re-configure ECU".
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4. When asked to re-apply Personalization select "YES" and follow the on screen instructions.
5. Follow the on screen instructions and select "Fault Code Diagnostics".
NOTE:
Fault codes must be cleared before TestBook/T4 is disconnected.
6. Clear any fault codes that are stored.
7. Disconnect TestBook/T4 from the vehicle.
Land Rover Range Rover Technical Service Bulletin # TEC700304 Date: 040618
Brakes - Parking Brake Cable Squeaks On Bumps
No: 70/03/04/NAS
Ref:
Issue: 1
Date: June 18, 2004
Squeak Noise from Handbrake Grommet
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
SITUATION:
SQUEAK EVIDENT IN PASSENGER COMPARTMENT
The customer may complain of a squeaking noise heard during suspension articulation in dry weather as when traversing a speed bump. The noise
may appear to be originating from a range of locations (the rear suspension, hand brake lever or rear of the center console) in the middle of the
vehicle. The handbrake cable passes through a support bracket grommet under the vehicle. During suspension articulation contact between the cable
outer sleeve and grommet can generate a squeaking noise, which can be heard inside the vehicle.
RESOLUTION:
INSPECT FOR SOURCE AND LUBRICATE GROMMET
A witness mark may be present on the cable sleeve, extending either side of the bracket grommet. Lubrication of the grommet and cable should
eliminate the problem.
PARTS INFORMATION
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Material allowance claim OTHER = $0.55 Normal warranty policy and procedures apply.
REPAIR PROCEDURE
APPLY KRYTOX TO BUSHING
1. Remove any debris, which may have accumulated in the bracket grommets.
NOTE:
The bracket should be located perpendicular to the cable on the rear suspension upper control arm when the vehicle is in standard ride
height and resting on the wheels.
111
2. Inspect the cable support brackets (left-hand and right-hand) and verify correct alignment. (Figure 1)
3. If the bracket is misaligned, loosen the bracket fastener and perform the following:
^ Position the bracket so that the grommet is perpendicular to the travel of the cable.
^ Hold the bracket in position to prevent rotation. Tighten the fastening bolt to 5 Nm (4 lbf.ft).
4. Apply Krytox spray (LRN100050S) around the interface of the handbrake cable and grommet. (Arrowed in Figure 1)
5. Assess vehicle to determine if the squeak has been eliminated and apply additional Krytox if necessary.
Land Rover Range Rover Technical Service Bulletin # TA036003 Date: 030625
Suspension - Front Suspension Knocking Noise
TA03 6003
TECHNICAL ALERT
June 25, 2003
ATTENTION:
Service Manager
Service Advisor
Technician
Knocking from Front Suspension While Cornering
SITUATION
The customer may complain of a "knock" from the front suspension area during cornering or when entering driveways at an angle.
RESOLUTION
The sound may be the result of a torque relaxation of anti-roll bar retaining nuts.
Manufacturing tool processes may not have consistently tightened the nuts to the correct specification.
REPAIR PROCEDURE
1. Raise the vehicle on a lift.
2. Remove the heat shield retaining nuts securing the shield to the body.
3. Remove the heat shield retaining bolts securing the shield to the sub-frame and lower the heat shield.
4. Verify that the nuts securing the anti-roll bar to the sub-frame are tightened to a torque of 19 Nm (14 lbf.ft.)
5. Install the heat and tighten all fasteners.
6. Lower the vehicle.
WARRANTY CLAIMS:
112
60.10.89/33 Time 0.20 hrs.
Confirm correct anti-roll bar fastener torque
FAULT CODE: G
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.Land Rover Range Rover Technical Service Bulletin # TEC762203 Date: 031205
Steering - Steering Column Rubbing Noise When Turning
No: 76/22/03/NAS
Ref:
Issue: 1
Date: 12/05/03
Steering Column Cowl Rub
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
SITUATION:
STEERING COLUMN COWL CONTACTS THE STEERING WHEEL
The column cover may have been incorrectly installed during a repair procedure permitting contact with the steering wheel and causing a rubbing
noise. The information in the current RAVE Workshop Manual is incomplete and does not indicate all required steps.
RESOLUTION:
REPOSITION THE COWL FOR CORRECT CLEARANCE
Should a customer express concern regarding the above, follow the rectification procedure outlined in this bulletin.
PARTS INFORMATION:
No parts required
AS400 WARRANTY CLAIMS (CANADA ONLY)
57.40.29 Time 0.10 hrs.
Correctly install steering cowl column
FAULT CODE: A
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
INSTALL COLUMN COWL USING NEW PROCEDURE
NOTE:
The steering column cowl or "nacelle" procedure in the Workshop Manual (57.40.29) will be updated at the next available opportunity to reflect
the procedure detailed below.
1. Fully extend the steering column for access. Wheel removal is not required.
113
2. Remove three Torx screws securing steering column cowl. (Figure 1)
3. Release the cowl from the clips securing the assembly to the column extension bellows.
4. Remove the steering column cowl.
5. Push the steering column extension bellows fully toward the front of the vehicle.
CAUTION:
The lower half of the cowl must not come in contact with the steering wheel.
6. Position the lower half of the cowl to the column assembly.
7. Install and tighten the two T25 Torx screws.
8. Install the upper half of the cowl.
9. Verify that the clips engage with the lower half.
CAUTION:
The upper part of the cowl must not come in contact with the steering wheel.
10. Verify that there is no contact between the upper or lower cowl components and the steering wheel.
11. Secure the upper half of the cowl into position with the remaining T20 Torx screw.
12. Install and secure steering column extension bellows to the assembled cowl.
Land Rover Range Rover Technical Service Bulletin # TEC570605 Date: 050623
Interior/Steering - Steering Wheel Trim Delamination
No: 57/06/05/NAS
FGN LM2JJ-04
Ref:
Issue: 1
Date: 23 June 2005
Steering Wheel Trim Deterioration
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
SITUATION:
STEERING WHEEL TRIM DELAMINATES
A customer may complain of paint finish deterioration or delaminating from the steering wheel spoke covers. The original paint surface can react to
certain chemicals, for example those found in some after-shave or sun-tan lotions, causing the paint to lift.
RESOLUTION:
INSTALL REPLACEMENT STEERING WHEEL TRIM KIT
114
Should a customer complain of steering trim deterioration refer to the Repair Procedure detailed in this bulletin to replace the trim covers.
PARTS INFORMATION:
DDW WARRANTY CLAIMS:
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.
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
INSTALL REPLACEMENT STEERING WHEEL TRIM
WARNING:
All Cautions and Warning relating to steering wheel removal in the Workshop Manual must be observed.
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LM New
Range Rover/2OO5 > Workshop Manuals > Range
Rover Workshop Manual - Service Procedures >
Bookmark "STEERING/REPAIRS" > Link "Steering
wheel"
1. Refer to GTR Workshop Manual section 57.61.01 and remove the steering wheel.
2. Remove the four torx retaining screws. (Figure 1)
3. If equipped with heated steering wheel, release the electrical connector from the steering wheel heating element. (Arrowed in Figure 1)
115
4. Release the back cover from the wheel frame.
5. Release the lower spoke covers. (Figure 2)
6. Release the plastic securing tangs from the wheel frame and remove the upper spoke covers. (Figure 3 Insert)
7. The new spoke covers can be identified by the markings on the rear of the cover.
^ "u.re" - lower right hand spoke
^ "uli" - lower left hand spoke
^ "ore" - upper right hand spoke
116
^ "o.li" - upper left hand spoke
CAUTION:
the electrical wire on vehicles equipped with heated steering wheels must be carefully and correctly installed.
8. If equipped, orient heated steering wheel wire to avoid pinching.
9. Install the lower spoke cover and ensure the securing tangs click into the wheel frame.
10. Position the upper and lower spoke covers with the guides aligned.
11. Apply medium pressure and press the upper and lower parts together until they click into position.
12. Install the back cover onto the wheel frame.
13. If equipped, connect the electrical connector for the steering wheel heating element. (Arrowed in Figure 1)
14. Install the four torx retaining screws. (Figure 1)
15. Refer to GTR section 57.61.01 and install the steering wheel.Land Rover Range Rover Technical Service Bulletin # TEC600105 Date: 050316
Suspension - Air Suspension Diagnostic Guidelines
No: 60/01/05/NAS
FGN LM204
Ref:
Issue: 1
Date: March 16, 2005
Air Suspension Diagnostic Guidelines
AFFECTED VEHICLE RANGE:
Range Rover (LM) All
SITUATION:
INCORRECTLY DIAGNOSED EAS SYSTEM FAULTS
The EAS control unit stores fault codes for numerous air suspension system component failures. In the majority of cases, changing the ECU will
re-activate the system and appear to have rectified the fault. However, the root cause of the problem may well be in a system component rather than
the ECU.
RESOLUTION:
FOLLOW RECOMMENDED DIAGNOSTIC PROCESS
Should a customer express concern regarding air suspension, refer to the Diagnostic Procedure detailed in this bulletin for correct system diagnosis
before changing the ECU. There are only four reasons for changing the Air Suspension ECU:
^ T4 Fault Code 52 (ECU Memory Fault)
^ T4 Fault Code 53 (ECU Fault)
^ T4 Fault Code 55 (ECU Calibration Fault)
^ Communications to the EAS ECU have failed.
Other faults are component-related and require system diagnosis and troubleshooting.
117
PARTS INFORMATION
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
REPAIR PROCEDURE
PRELIMINARY EAS SYSTEM EVALUATION
1. Determine if one of the following faults exists:
^ T4 Fault Code 52 (ECU Memory Fault)
^ T4 Fault Code 53 (ECU Fault)
^ T4 Fault Code 55 (ECU Calibration Fault)
^ Communications to the EAS ECU have failed.
NOTE:
Problems other than the communications fault and Codes 52, 53, and 55 are due to other components, wiring or air harness faults. Normal
fault diagnosis is required to determine component and harness faults.
CAUTION:
The solving of height sensor problems should always be accompanied by re-calibrating the vehicle trim heights.
2. If any other problem is diagnosed that appears to be ECU-related, identify the root cause in the system.
3. If one of the above faults is determined, go to the appropriate diagnostic section for that fault in this bulletin. Follow the procedures detailed
for the Fault Codes diagnosis before replacing the ECU.
T4 FAULT CODE 52 (ECU MEMORY FAULT)
1. Start T4 diagnostic session.
2. Enter Vehicle VIN and follow on-screen instructions.
3. Select 'Vehicle Configuration'.
4. Select 'Reconfigure ECUs'.
NOTE:
GTR lookup sequence is as follows: GTR Home > NAS > Service Information/LM Range Rover/2005 > Electrical Library > "Range
Rover 2002MY ON Electrical Library" > Bookmark "CONNECTOR" > Select the connector number link referenced in the text of this
TIB.
NOTE:
GTR provides the Right Hand Drive location of the ECU. The correct Left Hand Drive ECU location is "Behind the RH side of facia"
118
CAUTION:
All terminals should be seated to the same level. A fully seated terminal will be located within 1 mm of being flush with the connector
surface.
5. If the fault code is not cleared perform the following:
^ Check EAS ECU connection C0867 for loose connectors or corrosion.
^ Re-secure or clean connection as necessary.
^ Check connection C2030 for loose connection or corrosion.
^ Examine the connector mating-face to verify all terminals are fully seated.
^ Confirm all terminals are fully seated by pushing each wire from the back of the connector into the connector housing. Any unseated
terminals will "click" home.
^ Check battery ground connections C0821 and C0553.
^ Clean connections as necessary and verify that connectors C0821 and C0553 are tightened to 10 Nm (7 lbf ft).
6. Determine if fault codes have been cleared as follows:
^ Start T4 diagnostic session.
^ Enter Vehicle VIN and follow on-screen instructions.
^ Select 'Vehicle Configuration'.
^ Select 'Reconfigure ECUs'.
7. If the fault code is cleared the failure has been fixed.
8. If the fault code is not cleared replace the EAS ECU.
T4 FAULT CODE 53 (ECU FAULT)
1. Refer to GTR section 60.50.04 and replace the EAS ECU.
T4 FAULT CODE 55 (ECU CALIBRATION FAULT)
1. Refer to GTR section 60.50.04 and replace the EAS ECU.
COMMUNICATIONS TO THE EAS ECU HAVE FAILED.
1. Verify that the T4 connector is correctly coupled to the vehicle diagnostic connector.
NOTE:
GTR lookup sequence is as follows: GTR Home > NAS > Service Information/LM Range Rover/2005 > Electrical Library > "Range
Rover 2002MY ON Electrical Library" > Bookmark "CONNECTOR" > Select the connector number link referenced in the text of this
TIB.
2. Check for good battery ground connection on pins 4 and 5 of the diagnostic connector (C0040).
3. Check for battery power at pin 1 (ignition positive) and pin 16 (battery positive) of the diagnostic connector (C0040).
4. If no power is evident, check fuse 5 (ignition -7.5 amp) and fuse 15 (battery feed -5 amp) at the passenger fuse box.
5. If the checked fuses are open/blown, replace fuses as necessary.
6. Ensure that no short circuit is present and T4 connections are good.
7. Perform the following check for battery power at EAS ECU:
^ Check fuse 57 (15 amp) in passenger fuse box.
^ If fuse 57 is open/blown check connector C0582, cavity 3, at the top of the passenger fuse box for loose connections or corrosion.
Re-secure or clean terminals as necessary.
119
^ Check connectors C0867 and C2030 at the EAS ECU for loose connections or corrosion. Re-secure or clean terminals as necessary.
^ Install Connectors C0867 and C2030 and test for communication.
^ If there is no communication, check for battery power at connector C2030, cavity 10.
^ If there is no power at cavity 10, check fuse 57 (battery feed 15 amp) in passenger fuse box.
8. Check for battery ground at EAS ECU, connector C2030, cavity 5.
9. If there is no ground at C2030 cavity 5 perform the following:
^ Check harness run for continuity.
^ Check for proper connections at ground header K109, connector C0285, and ground eyelet C0553.
10. Check for continuity between connector C0867, cavity 2 and instrument pack connector C0234, cavity 8.
11. If there is no continuity perform the following:
^ Check harness run for continuity.
^ Check for proper connections at sealed joints X18827 and X18836.
12. Check for continuity between connector C0867, cavity 20 and instrument pack connector C0234, cavity 9.
13. If there is no continuity perform the following:
^ Check harness run for continuity.
^ Check for proper connections at sealed joints X18826 and X18835.
14. Check for continuity between pin 8 of diagnostic connector (C0040) and pin 1 of instrument pack connector (C0233).
15. If there is no continuity perform the following:
^ Check harness run for continuity.
^ Check for proper connections at sealed joint X183.
16. Check instrument pack for faults and repair as necessary.
17. If any repairs have been completed, check for communication.
18. If the instrument pack is functional and the checks and connection validations have not resolved the issue, replace the EAS ECU with a new
unit (RQ1000013).
Land Rover Range Rover Technical Service Bulletin # G97-05 Date: 970314
Air Bag - Safety Label Instruction
Bulletin: G97-005
Section: General
Date: 14 Mar 1997
Model: All
Subject:
Air Bag Safety Labels for Owner Application
Owners of Range Rover Classic, Range Rover 4.0/4.6 and Discovery models equipped with driver and passenger side airbags are being contacted by
Land Rover North America to inform them of the safety aspects of air bag deployment. Included with the letter is a set of warning labels and
instructions for placing those labels on the sun visor of each vehicle type.
We have appended copies of the letter and label instructions to this Service Bulletin. Also enclosed with this distribution are a number of complete
mailers for your use. We recommend that the labels in the mailer be applied to vehicles in your inventory. Additional label sets can be obtain by
contacting LRNA Product Support.
120
This action by Land Rover is intended to responsibly respond to the media attention recently directed at air bag deployment incidences which have
caused injury to improperly positioned occupants, especially children. We urge you to follow up with your customers to ensure that any questions
they may have about safe positioning of infant seats in Land Rover vehicles are answered. You should emphasize the same key points made in the
owner letter:
^ NEVER put a rear facing child seat in the front passenger seat of a Land Rover (or any other vehicle) equipped with a passenger side air bag.
^ Always place children under 12 years of age in the back seat.
^ Use a child seat or a booster seat which is appropriate to the child's age and weight. Follow the seat manufacturer's instructions to properly
anchor any child seat.
^ Always move both the driver and passenger seats as far back as safely possible from the air bag location in the vehicle.
Please note that the "800..." phone number to the National Mobility Equipment Dealers Association in the owner letter is incorrect. Should you have
inquiries, please advise the owner that information about pedal extenders can be obtained by calling the National Mobility Equipment Dealers
Association at 1-813-932-8566.
Land Rover Range Rover Technical Service Bulletin # TEC600103 Date: 030117
Suspension - Air Suspension Lamp ON/Inoperative
No: 60/01/03/NAS
Ref:
Issue: 1
Date: 01/17/03
Air Suspension Pressure Switch Failure
AFFECTED VEHICLE RANGE:
Range Rover (LP) All
SITUATION:
WARNING LIGHT ILLUMINATES AND AIR SUSPENSION INOPERATIVE
A customer may complain of inoperative air suspension and/or that an air suspension warning light has illuminated.
RESOLUTION:
REPLACE PRESSURE SWITCH AS FIRST REPAIR EFFORT
Interrogation of the Air Suspension Electronic Control Unit (ECU) with TestBook/T4 may a fault code inlet solenoid valve stuck open". The code
could mean that the pressure switch is faulty. The code does not necessarily mean that the valve block must be replaced. The pressure switch may
stick intermittently and TestBook/T4 has not diagnosed the fault correctly.
After interrogation of the ECU with TestBook/T4 determines the fault code "inlet solenoid valve stuck open," replace the pressure switch as the first
effort to repair the vehicle.
PARTS INFORMATION:
ANR3902 Air suspension pressure switch Qty 1
Locally sourced:
^ Loctite 572 Low strength sealant
WARRANTY CLAIMS:
60.50.07 Time 0.70 hrs.
Install replacement
FAULT CODE: Z
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
121
REPLACE AIR SUSPENSION PRESSURE SWITCH
1. Refer to RAVE Workshop Manual, section 60.50.07 and remove pressure switch.
2. Apply Loctite 572 to the thread of the replacement pressure switch
3. Tighten the new switch to 13 Nm (10 lbf.ft).
4. Raise and lower the suspension.
5. If the air suspension is still inoperative then further investigation will be required.
Land Rover Range Rover Technical Service Bulletin # TECSB276 Date: 050316
Campaign - Engine Harness Inspection/Re-Routing
No: SB276
Ref:
Issue: 1
Date: 16 March 2005
Engine Harness Inspection / Repair
AFFECTED VEHICLE RANGE:
Range Rover (LP) XA403796 to 1A458539
SITUATION:
ENGINE HARNESS DAMAGE / CHAFE
The original harness routing path can permit the engine harness to chafe on the engine compartment fuse box bracket. Extended chafing can result in
electrical short or system malfunction.
RESOLUTION:
INSPECT AND REPOSITION HARNESS
At the next service opportunity inspect the harness for damage. If damage is determined, repair the harness using harness repair kits. If damage is
severe, contact the Land Rover HelpLine for consultation and authorization to replace the harness. Route the engine harness as specified in this
Bulletin.
PARTS INFORMATION:
NOTE:
Supply of engine harnesses is extremely limited. DO NOT order harnesses for stock.
1. Contact the Technical HelpLine to determine if a replacement harness is required for repair after inspection indicates that it MIGHT be.
2. * VIN ranges are approximate. A label with part number is fitted to the harness adjacent to the battery box. Prior to ordering a replacement
harness the harness part number on the vehicle must be checked to ensure that the correct harness is ordered.
122
NOTE:
Repair connectors are supplied in packs of five. Due to limited availability, please restrict parts order to one pack of each of these part numbers.
TOOLS
Ratchet crimping tool
Hot air gun
DDW WARRANTY CLAIMS:
Warranty claims should be submiffed quoting program code B276 together with Option Code "X".
Option Code X requires entry of the relevant SROs from the Table, and the parts used for the repair.
This will result in payment of stated time and where applicable parts expense.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
INSPECT AND RE-ROUTE ENGINE HARNESS
1. Release and remove the battery cover.
CAUTION:
After the ignition is switched off, the navigation computer remains "on" for approximately 55 seconds. It then performs a memory back-up
operation for approximately 5 seconds before shutting down into "sleep" mode.
If the vehicle battery is disconnected during this critical 5-second backup period, it can cause a memory error in the navigation computer. This
can render the computer unusable, so that when power is reapplied, the satellite navigation system will not power up, giving a blank screen.
2. Refer to Service Action Bulletin H269 for information governing battery removal.
3. After waiting two minutes from ignition shut-off, disconnect the battery ground cable.
4. Remove 3 bolts securing the engine compartment fuse box to the retaining brackets. (Figure 1)
5. Move the fuse box aside.
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6. Determine if the harness lead is incorrectly routed between the alarm horn and fuse box bracket. (Figure 2)
7. If incorrectly routed, inspect the engine harness for damage caused by a foul condition on the fuse box mounting bracket.
NOTE:
A thorough examination of the engine harness will ensure that no other damage has occurred as the result of harness routing.
8. If the engine harness is damaged but repairable, perform the following repair process:
^ Remove outer cable sheathing to exposed damaged wires.
^ Repair individual leads using repair wires of correct cross section.
^ Insulate the repaired engine harness damaged area using electrical tape.
9. If it is believed that the engine harness is beyond repair consult with the Technical HelpLine to verify that the replacement option is the best
solution.
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LP Range
Rover/2002 > Workshop Manuals> Range Rover >
Bookmark "86 - Electrical" > "HARNESS - ENGINE - V8
- FROM 99MY" link
10. If it is determined that the harness is beyond repair, refer to GTR section 86.70.17 and replace the harness.
11. During the repair or replacement process, perform the following:
^ Disconnect the alarm horn connector.
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^ Position the engine harness between the battery box and the alarm horn. (Figure 4 and Figure 5)
^ Ensure the engine harness is situated below the alarm horn connector.
^ Connect the alarm horn connector.
12. Position the fuse box to the fuse box retaining brackets.
13. Verify that the wiring to the fuse box is not trapped between the fuse box and bracket.
14. Start the three fuse box attachment bolts and tighten to 2.5 Nm (1.8 lbf.ft).
15. Connect the battery ground cable.
16. Install and secure the battery cover.
CAMPAIGN LABEL
NOTE:
Campaign labels are no longer required for Service Action Campaigns.
DisclaimerLand Rover Range Rover Technical Service Bulletin # TEC760500 Date: 001027
Body - Front Door Latch Won't Unlock
No: 76/05/00/NAS
Ref:
Issue: 1
Date: 10/27/00
Super-locked Door Latch Removal
AFFECTED VEHICLE RANGE:
Range Rover (LP) All
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SITUATION:
FRONT DOOR LATCH FAILS IN THE SUPER-LOCK MODE
The customer may experience a front door that will not open after it has been locked in the super-lock mode. The latch mechanism can remain
locked even though the remote or the key has been used to unlock it. Other latches in the vehicle will usually unlock correctly.
RESOLUTION:
ACCESS FRONT DOOR LATCH AND DISENGAGE SUPER-LOCK PAWL
From the inside of the vehicle it is possible to access the jammed door latch with the appropriate tools and disengage the super-lock pawl following
the instructions in this TIB.
PARTS INFORMATION:
FQJ103280 Latch Assembly RH Qty 1
FQJ103290 Latch Assembly LH Qty 1
WARRANTY CLAIMS:
76.37.89/39 Time 0.30 hrs.
Release jammed lock mechanism
FAULT CODE: F
Normal warranty policy and procedures apply
REPAIR PROCEDURE
1. Enter the vehicle through the passengers side.
2. Lower the driver's side door window to the fully down position.
3. Tape the edge of the window to protect the area during the following steps.
4. Inspect the door latch with the aid of a flash light and identify the white plastic retainer for the super-lock pawl spring. (Figure 1)
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5. Position a long (18") slender screw driver onto the plastic cover. (Figure 2)
CAUTION:
In the next step exercise care to only apply enough force to break the plastic housing.
^ Too much force could result in damage to surrounding components or the door panel.
^ Windows with applied tints can be damaged by the screwdriver.
6. Tap the screwdriver with a hammer to break the plastic cover.
7. Remove the released spring.
8. Move to the exterior of the door and perform the following:
^ Grasp the outer door handle.
^ Apply body pressure against the outer door surface to reduce load on the latch.
^ Tap the lock assembly motor repeatedly with the screwdriver (Figure 1) until the super-lock pawl releases.
9. Release body pressure and open the door.
10. Follow Workshop Manual Section 76.37.12 procedures to replace the door latch assembly with a new unit.
11. Remove protective tape and verify proper latch operation.
Land Rover Range Rover Technical Service Bulletin # TEC7615032 Date: 040604
Body - Lock/Latch Systems Diagnosis/Repair
No: 76/15/03/NAS
Ref:
* Issue: 2
Date: June 04, 2004 *
Troubleshooting Problems with Handles, Locks and Latches
AFFECTED VEHICLE RANGE:
Range Rover (LM) All
Updated information is shown with asterisks.
SITUATION:
CUSTOMER DIFFICULTIES WITH LOCKING/LATCHING SYSTEM
The customer may experience difficulties with the locking system and latch mechanisms. A range of situations can contribute to these situations. To
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avoid the need to change side door latches unnecessarily it is necessary to identifying the root causes.
RESOLUTION:
INVESTIGATE AND DETERMINE ROOT CAUSE OF PROBLEM
NOTE:
If an obvious cause for an observed or reported concern is found, correct the cause before proceeding through the Symptom Chart.
PARTS INFORMATION:
REFER TO MICROCAT EPC
WARRANTY CLAIMS:
INFORMATION ONLY
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
128
129
130
131
132
SYMPTOM AND PROBABLY CAUSE MATRIX
Land Rover Range Rover Technical Service Bulletin # TEC761505 Date: 050926
Body - Door Cannot Be Opened From Inside/Outside
No: 76/15/05/NAS
FGN LM501-03
Ref: 76/15/03/NAS
Issue: 1
Date: 26 September 2005
Door Latch Mechanism Function
AFFECTED VEHICLE RANGE:
New Range Rover (LM)
Up to 5A180579
SITUATION:
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DOOR LATCH ASSEMBLY FAILS TO OPERATE
A condition can occur where the door cannot be opened from either the interior or exterior handles, despite the locking mechanism functioning
correctly when using a key or the remote. The internal lever on the door latch is jammed in the down position also. Remote or key effectiveness is
indicated by the door lock-button state (up moves or down as expected).
RESOLUTION:
RELEASE AND REPLACE JAMMED LATCH MECHANISM
Should a customer express concern regarding the above, refer to the Service Procedure detailed in this Bulletin to release the affected door.
Following jammed latch release, the door latch must be replaced.
In cases where the door opens, but from only one of the handles, follow the trouble shooting guide detailed in TIB 76/15/03/NAS (Edition 2)
Troubleshooting Problems with Handles, Locks and Latches.
PARTS INFORMATION:
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
OPEN A JAMMED FRONT DOOR
1. Unlock all doors.
2. Verify that all door lock-buttons are in the UP position indicating an unlocked condition.
3. Partially open the rear door behind the affected front door. (Figure 1)
CAUTION:
Protection in the area of the front-edge of the rear door and the rear-edge of the front door is required to prevent paint damage.
4. Place tape or other suitable protection on the front-edge of the rear door and the rear-edge of the front door. (Figure 1 and Figure 2)
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5. Identify the grommet covering the latch adjustment screw of the front door latch. (Figure 1)
6. Remove the grommet covering the latch adjustment screw. (Figure 2)
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7. Using a suitable implement (bent wire or similar), locate and hook the adjustment screw. (Figure 3)
NOTE:
An audible click will be heard as the mechanism is released.
8. Release the mechanism using one of the following methods:
^ Move the adjuster screw up and down providing the small amount of movement that may release the mechanism.
^ Pull the screw in the upward direction using modest force.
9. When the lock mechanism releases, open the door.
10. Go to section "Replace Affected Door Latch."
OPENING A JAMMED REAR DOOR
1. Unlock all doors.
2. Verify that all door lock-buttons are in the UP position indicating an unlocked condition.
3. Fully open the window on the affected rear door.
4. Carefully remove the window-glass outer waist seal. (Figure 4)
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5. Look through the space between the door glass and the exterior door panel and locate the exterior release-lever of the door latch inside the
door cavity.
CAUTION:
Protection is required in the area of the forward glass-runner to prevent paint damage.
6. Place suitable protection in the area of the forward glass-runner to prevent paint damage. (Figure 5)
7. Using a slender implement with notched end, locate and hook the lever. (Figure 5)
NOTE:
A click will be heard as the mechanism is released.
8. Pull lever in a rearward/upward direction.
9. When the mechanism has been released open the door.
10. Go to section "Replace Affected Door Latch."
REPLACE AFFECTED DOOR LATCH
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LM Range Rover/2004 > Workshop Manuals > Service Procedures > Bookmark
"DOORS/REPAIRS" > "Latch - front door" link. The same procedure applies to front and rear door latch replacement.
1. Refer to GTR Workshop Manual section 76.37.12 and replace the affected door latch assembly.
2. If excessive force is required to open the door after replacing the door latch, perform the following:
^ Check for preload on the interior or exterior release handles.
^ Verify that both handles return fully
3. Adjust door latch tensioning screws if required as follows:
^ Open affected front or rear door.
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^ If installed, remove grommet from the affected door (Figure 6 and Figure 7) for access to the door lock tensioning screw.
NOTE:
The door lock tensioner screws rotate counterclockwise on LH doors, clockwise on RH doors to release tension.
^ Release the door lock tensioning screw two turns.
^ Tighten the door lock tensioning screws to 4 Nm (3 lbf ft).
4. Install the door lock tensioning screw grommet.
5. Close front and rear doors.
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DisclaimerLand Rover Range Rover Technical Service Bulletin # TEC7612032 Date: 060104
Body - Front/Rear Door Difficult to Open
No: 76/12/03/NAS
Ref:
*Issue: 2*
*Date: January 4, 2006*
Difficult Door Latch Operation
Updated information is shown with asterisks.
AFFECTED VEHICLE RANGE:
*Range Rover (LM) ALL*
SITUATION:
FRONT AND/OR REAR DOOR DIFFICULT TO OPEN
The customer may complain that extra effort is required to operate the front or rear door latches. Free play in the door latch release cable may be the
cause of this complaint.
RESOLUTION:
ADJUST DOOR LATCH *ADJUSTER* SCREWS
When the above complaint is verified, perform the adjustment procedure in this TIB to improve the ease with which the doors may be opened.
PARTS INFORMATION:
No Parts Required
WARRANTY CLAIMS
REPAIR PROCEDURE
DOOR LOCK ADJUSTMENT
1. Open front and rear doors.
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2. Remove the grommet from the front doors (Figure 1) and the rear doors (Figure 2) for access to the door lock *adjuster* screw.
CAUTION:
The screw threads are counter-clockwise on LH doors and clockwise on RH doors.
3. Release the door lock *adjuster* screw on the affected door(s) two turns.
4. Tighten the door lock *adjuster* screws to 4 Nm (36 lbf.in.).
5. Install the door lock *adjuster* screw grommets.
6. Close front and rear doors.
DisclaimerLand Rover Range Rover Technical Service Bulletin # TEC760104 Date: 040123
Body - Door Mirror Vibration/Looseness
No: 76/01/04/NAS
Ref: TA037603
Issue: 1
Date: 23 January 2004
Loose Door Mirror Correction
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AFFECTED VEHICLE RANGE:
New Range Rover (LM) up to 4A144688
SITUATION:
MIRROR VIBRATION OR OBSERVED LOOSE CONDITION
On some vehicles it may be noticed that the exterior mirror glass assembly is loose in its housing. Vibration over uneven surfaces may be evident.
The information in this bulletin supersedes and replaces that published in Technical Alert TA047603.
RESOLUTION:
TIGHTEN MIRROR FASTENERS
Should a customer complain of the vibration or of a loose condition, ensure that the proper torque has been applied to the attachment screws inside
the mirror housing.
PARTS INFORMATION:
Locally sourced
^ Blue Loctite 248
AS400 WARRANTY CLAIMS (CANADA ONLY)
76.10.89/80 Time 0.10 hrs.
Tighten door mirror fasteners - both sides
FAULT CODE: G
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
TIGHTEN DOOR MIRROR ATTACHMENT SCREWS
1. Remove the access cover from the underside of the exterior door mirror.
2. Tighten the four fasteners securing the door mirror to the mirror housing to 14 Nm (10.3 lbf.ft.). (Arrowed Figure 1).
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3. Install the removed access cover.
4. Go to Step 1 and repeat the torque procedure on the unrepaired side.
Land Rover Range Rover Technical Service Bulletin # H201 Date: 991217
Campaign - Windshield Finisher Wind Noise Reduction
No: H201
Ref: 76/09/97/NAS
Issue: 1
Date: 12/17/99
SERVICE ACTION:
Upper Windshield Finisher Wind Noise Reduction
AFFECTED VEHICLE RANGE:
RANGE ROVER (LP) YA427112 to YA430888
SITUATION:
GAP BETWEEN FINISHER AND WINDSHIELD ALLOWS VIBRATION
Due to inconsistent manufacturing processes, some vehicles may have a gap between the upper windshield finisher and glass. While traveling at
highway speeds, this gap can cause a wind noise.
RESOLUTION:
MODIFICATION OF A-PILLAR FOAM/SEALING OF FINISHER TO GLASS
NOTE:
All vehicles currently held in inventory as new vehicles should be inspected, and if necessary, repaired prior to sale.
Prior to delivery of new MY2000 Range Rover vehicles inspect to determine if a correction has been performed at the port of entry. If required,
perform the repair operations in this TIB. Customer owned vehicles within the VIN range should be inspected, and if necessary repaired at the next
service opportunity.
The repair involves repositioning the foam strip along the edge of the A-pillar, removal of some material from a foam filler block and sealing the
leading edge of the upper windshield finisher to the glass using an elastomeric sealant.
PARTS INFORMATION:
LRN0002LABEL Campaign Label Qty 1
LRNA25223 Elastomeric Sealant (as required)
WARRANTY CLAIMS:
H201 (Option 1) Time 0.15 hrs
Inspect vehicle to determine if previous repair has been completed
H201 (Option 2) Time 0.40 hrs.
Remove both side A-pillar trim pieces and correct location of foam. Bond finisher to glass
Material Allowance is included in the time allowance for repair
Normal warranty policy and procedures apply
REPAIR PROCEDURE
INSPECTION
142
NOTE:
If a dab of white paint is found on the upper retaining screw of the driver's side exterior A-pillar trim, this repair has already been performed.
(Figure 1)
1. Inspect to determine if the repair has previously been performed.
2. If the repair has been performed, go to "Campaign label installation" and install the campaign label. No further action is required.
3. If the repair has not been performed, continue with this procedure.
CORRECT FOAM PLACEMENT AND SEAL WINDSCREEN FINISHER
1. Remove the top three fasteners securing the A-pillar exterior trim.
2. Check to see if the end of the windscreen finisher has deformed the foam strip or the foam filler block. (Figure 2)
3. Carefully reposition the foam strip to its correct routing parallel to the edge of the A-pillar trim.
4. If the foam filler block is deformed, carefully remove some material from the block to eliminate the foul condition between the filler block and
the end of the windscreen finisher. (Figure 3)
143
5. Apply a small bead of elastomeric sealer underneath the leading edge of the windscreen finisher to bond finisher to glass as follows:
^ Insert the sealant applicator tip into the gap approximately 10 mm (3/8 in.) underneath the finisher.
CAUTION:
Sealant should not come out from underneath the finisher.
^ Slowly slide the applicator from the center towards the outer end of the finisher, applying a consistent bead of sealant underneath the
finisher.
^ Remove applicator and ensure lip of finisher lays against windshield glass.
NOTE:
Elastomeric bead must be between the finisher/glass interface to fill the gap between the two components.
^ Allow sealant to skin over (about 5 minutes), and remove any visible sealant from the windshield and finisher.
6. Install A-pillar fasteners, ensuring that the foam strip is lying on top of the windscreen finisher and is not crushed by the end as before.
7. Repeat steps 1-6 on opposite side trim.
8. Refer to TIB 76/09/97/NAS and verify that there is no lifting of the trim piece in the center of the windshield.
9. To indicate that the repair has been performed, apply a dab of white paint to the upper retaining screw head of the driver's side exterior
A-pillar trim.
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:
^ Service Action codes performed ("H201")
^ Your retailer code
^ The date of repair
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2. Peel the label back, apply to radiator support and roll the label with the special roller.
Land Rover Range Rover Technical Service Bulletin # TEC761803 Date: 031031
Power Windows - 'One Touch' Feature Inoperative
No: 76/18/03/NAS
Ref:
Issue: 1
Date: 10/31/03
One Touch Window Operation Fault
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
SITUATION:
ONE TOUCH MODE FUNCTIONS INTERMITTENTLY OR IS DEACTIVATED
The front glass will not close in one touch mode or the window may open automatically after initially closing in one touch mode. The window
channel seal may be compressing the anti-trap contact strip. This sends a false "trap" signal to the Body Control Unit (BCU), which in turn
deactivates one touch mode functionality.
RESOLUTION:
INSPECT AND IF INDICATED REPLACE ANTI-TRAP SENSOR
Should a customer complain about these symptoms, follow rectification procedure below to ensure the anti-trap pinch strip is functioning correctly
and is not compressed or pinched.
PARTS INFORMATION:
EJN000022PUY Finisher assembly - RH front door Qty 1
EJN000032PUY Finisher assembly - LH front door Qty 1
AS400 WARRANTY CLAIMS
76.31.89/41 Time 0.10 hrs.
Inspect and reposition anti-trap sensor
76.31.89/42 Time 0.80 hrs.
Inspect and install new anti-trap sensor. Perform resistance check
FAULT CODE S
DDW WARRANTY CLAIMS:
NOTE:
Claim 76.31.89/42 if the door finisher was removed but was not faulty and for connecting the anti-trap sensor.
DDW requires the use of casual part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
INVESTIGATE ONE TOUCH FUNCTION
1. Switch the ignition on.
145
2. Lower the window.
3. Lift the glass run seal (A in Figure 1) to release the anti-trap sensor (B in Figure 1)
4. Operate the window one touch mode.
5. If the window one touch mode operates, perform the following:
^ Rotate the anti-trap sensor inboard to move and reposition the active area of the anti-trap sensor away from the glass run seal.
^ Check the window one shot mode operation.
^ Close the window.
^ Switch off the ignition.
6. If the window one touch mode operates correctly, no further action is required.
7. If the window one touch mode does not operate, verify that anti-trap multiplug is connected as follows:
^ Refer to RAVE section 76.34.01 and remove the trim casing.
^ Verify that the anti-trap sensor is connected. (Arrowed in Figure 2).
^ If the anti-trap sensor multiplug is not connected, connect the multiplug.
^ Operate the window one touch mode and determine operability.
^ If the one shot mode operates correctly, install the trim casing as outlined in RAVE section 76.34.01.
8. If the anti-trap sensor multiplug is connected, test the anti-trap switch assembly as follows:
^ Refer to RAVE section 76.34.42 and remove the front door frame finisher.
^ Place the frame finisher on a bench and verify that the anti-trap sensor is not compressed.
^ Using a multimeter, check the resistance of the anti-trap sensor:
NOTE:
If the resistance is between 1100 ohms and 1300 ohms the anti-trap sensor has the correct values and the problem is elsewhere in the
system.
146
^ If the resistance is below 1100 ohms, replace the anti-trap sensor/frame finisher.
NOTE:
The door frame finisher should be installed from the rear of the door to the front of the door, concluding the operation in the front corner.
A rubber mallet can be used to knock the door frame finisher downwards into the front corner. This will ensure that the door frame finisher
does not trap the pinch strip.
9. Install the door frame finisher following the procedures in RAVE section 76.34.42.
10. Check the window one touch mode operation to ensure proper operation.
Land Rover Range Rover Technical Service Bulletin # TEC760502 Date: 020809
Body - Outside Mirror Vibration
No: 76/05/02/NAS
Ref:
Issue: 1
Date: 08/09/02
Outside Mirror Vibration
AFFECTED VEHICLE RANGE:
Range Rover (LP) Up to 2A461981
All vehicles with non Electro-chromic door mirrors
SITUATION:
DOOR MIRROR VIBRATION
The customer may complain that the non-electro-chromic external mirrors vibrate, distorting rearward vision. Insufficient internal damping of the
door mirror assembly can cause mirror vibration.
RESOLUTION:
REPLACE EXTERIOR MIRRORS
Where a complaint of the above is confirmed, replace the door mirror assembly and glass with the new specification parts.
PARTS INFORMATION:
CRB001720LML Mirror assembly, Primed RH Qty 1
CRB001730LML Mirror assembly, Primed LH Qty 1
CRB001760PMD Mirror assembly, Grained RH Qty 1
CRB001770PMD Mirror assembly, Grained LH Qty 1
CAUTION:
If no vibration is present, but a damaged mirror glass is being replaced on an original equipment mirror assembly, one of the two dampers on the
new style mirror glass must be removed. The inboard damper on LH mirrors and the outboard damper on the RH mirrors should be removed.
CRD000310 Glass Convex RH - Canada 1999 up Qty 1
CRD000340 Glass Convex RH - NAS (Canada up to 1999 MY) Qty 1
CRD000380 Glass, Flat LH - NAS/Canada only Qty 1
Locally Sourced:
^ Black polyurethane sealant
WARRANTY CLAIMS:
Grained door mirror assembly
76.10.52 Time 0.20 Hrs
Install Door mirror assembly
76.11.11 Time allowance: 0.10 Hrs
Install Glass
Sublet Time allowance: 0.30 Hrs
147
Paint door mirror assembly LH or RH - includes install glass
FAULT CODE: W
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
INSTALL NEW STYLE MIRRORS
CAUTION:
Vehicles from VIN YA430702 use LH threaded screws to secure the LH door mirror assembly to the door.
1. Refer to RAVE Workshop Manual repair 76.10.52 and remove the door mirror assembly.
2. If required, paint new door mirror assembly.
3. Install the new door mirror assembly.
4. Tighten door mirror assembly screws using the following sequence:
^ 1st - front lower
^ 2nd - top
^ 3rd - rear lower
NOTE:
Any visible gaps between the mirror base moulding and the door should be filled with polyurethane sealant to eliminate possible wind
noise.
5. Fill gaps at base with sealant.
6. Clean off all traces of excess sealant.
7. Select appropriate new glass for door mirror assembly.
8. Lift damper blades (arrowed in Figure 1) perpendicular to the glass back plate.
9. Move the glass motor manually within the door mirror assembly so the inboard end of the motor is fully extended.
10. Position the glass to the door mirror assembly and connect the 2 heater wire spade connectors.
11. Position the inboard damper blade into the door mirror assembly slot. (Figure 2)
12. Locate the inboard end of the glass onto the glass motor plate.
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13. Press on inboard side of the mirror glass to move the motor to the fully extended position.
14. Position the outboard damper blade in the door mirror assembly slot. (Figure 3)
15. Press the glass fully onto the glass motor plate.
16. Verify the glass is fully retained and both dampers are located.
17. Check full operation of the door mirror assembly.
Land Rover Range Rover Technical Service Bulletin # 12-07-96 Date: 961025
Engine Oil - Winter Driving Specification
NO.
12/07/96/US
DATE
10/25/96
SUBJECT
Engine Oil Winter Driving Specification
MODEL
Range Rover 4.0/4.6
Range Rover Classic
Discovery
Defender
DETAIL
In order to ensure full engine protection and consistent engine start-up in cold weather conditions it is important that Land Rover oil viscosity
recommendations be followed. It is particularly vital when temperatures fall below freezing, 0°C (32°F), that the recommended 5W/40 or 5W/30 oil
be used to ensure that proper cranking speeds can be obtained.
Information published in the Service Manual for NAS vehicles in some editions may be confusing. In some cases the entire range of engine
protection is not shown on the NAS page. Refer to the information below for accurate engine oil protection information.
ACTION REQUIRED
USE ONLY RECOMMENDED MULTI-GRADE OILS.
FOR WINTER DRIVING WITH TEMPERATURES ROUTINELY BELOW FREEZING, A MULTI- VISCOSITY 5 WEIGHT OIL IS
REQUIRED. 5W/40 Oil IS RECOMMENDED.
PARTS INFORMATION
Use only oils which meet the API service level specification "SG" or SH."
PROCEDURE
149
The following oil viscosity ratings may be used in the temperature ranges specified.
Winter conditions:
5W/30 -35°to +35°C(-31° to +95°F)
Winter or summer conditions:
5W/40 -35° to +45°C (-31° to 113°F)
5W/50 -35° to +55°C (-31° to 131°F)
Summer conditions only
10W/30 -10° to +35°C (+14° TO +95°F)
10W/40 -10° to +55°C (+14° TO +131°F)
WARRANTY
Oil changes after PDI are not reimbursable under warranty.
COMP. CODE
SROLand Rover Range Rover Technical Service Bulletin # TEC260203 Date: 030912
Cooling System - 'Check Coolant Level' Message Displayed
No: 26/02/03/NAS
Ref:
Issue: 1
Date: 09/12/03
False "Check Coolant Level" Message
AFFECTED VEHICLE RANGE:
Range Rover (LM) All
SITUATION:
"CHECK COOLANT LEVEL" MESSAGE DISPLAYS
The customer may complain that the Check Coolant Level message displays but that the fluid level in the reservoir is at the correct level by visual
inspection.
RESOLUTION:
COOLANT VISCOSITY VERIFICATION REQUIRED
To rectify the apparent inconsistency in the message when the level is visually correct, a careful coolant viscosity check is required. Incorrect
viscosity can lead to incorrect readings and the warning message display. Generally the sensors and expansion tank will not be the cause of the
misleading Instrument Pack message.
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TOOL INFORMATION:
RN6024 Texaco AFC AntiFreeze
WARRANTY CLAIMS:
Normal warranty policy and procedures apply. Material allowance is included in labor operation.
REPAIR PROCEDURE
TEST COOLANT SPECIFIC GRAVITY
CAUTION:
The low coolant sensing system will not work correctly if the specific gravity of the coolant mixture is incorrect. The specific gravity
requirement for New Range Rover is 1.075,with a 50% anti-freeze solution at 20°C (68°F). This protects to -36°C (-33°F).
NOTE:
Accurate testing equipment must be used to ensure that a precise measurement is made. The test MUST be conducted prior to any investigation,
or the replacement of the expansion tank assembly or the low coolant level sensor.
1. Verify the specific gravity of the coolant in the expansion tank is 1.075, with a 50% anti-freeze solution at 20 °C (68 °F) for protection to -36°
C (-33° F).Land Rover Range Rover Technical Service Bulletin # TEC260205 Date: 050217
Cooling System - 'Check Coolant Level Message' Displayed
No: 26/02/05/NAS
FGN LM303
Ref:
Issue: 1
Date: 17 February 2005
False Coolant Level Warning
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
SITUATION:
"CHECK COOLANT LEVEL" WARNING MESSAGE DISPLAYED
The vehicle may display the "Check Coolant Level" warning message even when the coolant level is visually within the correct range in the
expansion tank. Incorrect specific gravity of the coolant mix can result in the "check coolant level" warning message being displayed.
RESOLUTION:
VERIFY COOLANT SPECIFIC GRAVITY
If the customer complains of the above symptom, the specific gravity of the coolant MUST be checked prior to any other investigations or repair,
such as the replacement of the expansion tank assembly or low coolant level sensor. The low coolant sensing system will not work correctly if the
specific gravity of the coolant mixture is incorrect.
The specific gravity of a 50% anti-freeze solution at 20°C (68°F) is 1.075 (using a coolant specific gravity tester) and protects against freezing down
to -36°C (-33° F).
PARTS INFORMATION:
NOTE:
A 50% mix of water and coolant is required for a refill. Topping up with either blue coolant is permitted for recent vehicles with factory fill
BASF G48 coolant (blue). The 50% mix is required to obtain the correct specific gravity.
DDW WARRANTY CLAIMS:
CAUTION:
Mixing of the BASF G48 (blue) with Texaco XLC (orange) coolant can result in premature erosion of the cylinder heads or other cooling system
deterioration. Unapproved blending of coolants is to be avoided.
151
Warranty coverage could be affected by the use of unapproved coolants or the incorrect blending of fluids.
Information Only
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.Land Rover Range Rover Technical Service Bulletin # TEC120200 Date: 001222
Engine - Tapping/Rattling Noises
No: 12/02/00/NAS
Ref: WSM Section 12
Overhaul Manual
Replaces TIB 12/01/98/NAS
Issue: 2
Date: 12/22/00
Rocker Arm Rattle/Tapping Sound
AFFECTED VEHICLE RANGE:
RANGE ROVER (LP) WA382672 to YA437311
DISCOVERY SERIES II (LT)Up to YA265404
DISCOVERY (U) WA753113 to XA795263
SITUATION:
NOISE FROM ENGINE VALVE TRAIN/ROCKER ARMS
Customer complaints of a rattling/tapping noise from the engine found to originate from rocker shaft area may be the result of the hardened push-rod
cup being insecure in the rocker arm.
RESOLUTION:
NOTE:
This bulletin supersedes and replaces TIB 12/01/981NAS.
INSPECT AND REPLACE ROCKER ARMS
Investigate customer complaints of valve rattling/tapping noise on vehicles within the above VIN ranges and identify rocker arms with loose
push-rod cups. If noisy or loose rocker arms are encountered during the inspection, replace all rocker arms with updated parts.
PARTS INFORMATION
WARRANTY CLAIMS
Normal warranty policy and procedures apply.
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REPAIR PROCEDURE:
DETERMINE FAULTY ROCKER ARMS AND REPLACE
1. Refer to Workshop Manual, Section 12, Engine Repairs, and remove both rocker covers.
2. Determine that rocker arms with loose cups are the source of the noise.
3. Locate the rocker arm casting date code on each rocker arm.
CAUTION:
Only rocker arms with date codes '00' may be used to repair valve trains. Use of early production rocker arms may result in a reoccurrence
of the problem.
4. Refer to Overhaul Manual LRL0004ENG and replace all rocker arms manufactured prior to a '00' date code with new rocker arms having date
code '00' or above. (Figure 1)
5. Assemble and install rocker arm assemblies.
6. Install rocker arm covers.
7. Start the engine and confirm that the rattling/tapping noise has been resolved.
Land Rover Range Rover Technical Service Bulletin # NHTSA00V377000 Date: 001116
Recall 00V377000: Transmission Park Lock Failure
Certain sport utility vehicles fail to comply with the requirements of FMVSS No. 114, "Theft Protection." Water contamination of the automatic
transmission oil can lead to various failure modes of the transmission. One of these failure models results in incorrect operation of the park lock
function that could allow a vehicle to roll away if parked without the handbrake properly set.
Unintentional vehicle movement could result in a crash or personal injury.
Land Rover has not yet provided NHTSA with a remedy for this campaign.
Land Rover has not yet provided NHTSA with an owner notification schedule for this campaign. Owners who take their vehicles to an authorized
dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Land Rover at 1-301-731-9040.
Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).Technical
Service Bulletin # TEC440102 Date: 020816
A/T - ZF Transmission/Multiple Shift Concerns
No: 44/01/02/NAS
Ref:
Issue: 1
Date: 08/16/02
ZF Transmission Troubleshooting
AFFECTED VEHICLE RANGE:
Range Rover (LP) Prior to MY 2001
Discovery Series II (LT) Prior to MY 2001
Discovery Series I (LJ)
Defender (LD)
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SITUATION:
VARIOUS SYMPTOMS INDICATE TRANSMISSION FAULTS
A transmission complaint which follows known patterns can permit a very straightforward diagnosis provided that a logical process is followed. The
purpose of this bulletin is to streamline the procedures followed by Retailers for specific complaints in the following vehicle ranges:
^ Discovery Series II and Range Rover vehicles prior to 2001 MY - Slipping on acceleration, erratic upshifts, vehicle "jerks" while accelerating,
engine revs "flare" on upshifts, Fault reference #1 (page 2)
^ All Discovery (Series I and Series II), Classic, Defender and Range Rover vehicles prior to 2001 MY - Loss of drive/slipping Fault reference's #
2, # 3, # 4
^ All Discovery Series II, Range Rover 4.0 & 4.6 - Fault code P0734 (Bosch), 43 (GEMS) Fault reference # 5
^ Discovery Series II, Range Rover 4.0 & 4.6 to 1999 - Fault codes P0501, P1884 and P0722 Fault reference # 6
RESOLUTION:
ENHANCE RETAILER DIAGNOSTIC ABILITY
Following the procedures in this TIB, the Retailer will be able to quickly diagnose the above faults and understand the remedial action required. In
such cases the Retailer can expedite the repair without having to gain prior authorization. Land Rover continues to require the Retailer to complete
the ATER.
The ATER must be faxed to the Land Rover ZF Technical HelpLine in all cases along with details of fault codes where applicable from Testbook.
PARTS INFORMATION:
Refer to Parts Catalogs/Microcat
WARRANTY CLAIMS:
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
INVESTIGATE DISCOVERY SERIES II AND RANGE ROVER PRIOR TO MY 2001:
SHIFT PERFORMANCE TROUBLESHOOTING - FAULT REFERENCE # 1
1. Determine the validity of the customer complaint:
^ Slipping on 2-3, 3-4 shift or 4-3, 3-2 shift
^ Engine races or "neutrals out" on 2-3, 3-4 shift or 4-3, 3-2 shift
^ Harsh shift or "jerk" on 2-3 or 3-4 shift
^ Transmission slipping on kick-down
NOTE:
Customers may also describe a double shift or a jerk/delayed shift when accelerating or that the car seems to "neutral out" or downshift to
first when accelerating. These symptoms suggest an internal failure within the transmission. If an internal failure exists the fault will be
repeatable in nature and WILL NOT be intermittent. Should the customer describe an intermittent problem or the dealer is unable to
reproduce the customer complaint please contact the Land Rover ZF HelpLine for further assistance.
CAUTION:
Oil levels must be checked COLD with engine running. Refer to the following documents for additional guidance.
^ Oil level setting Service Alert SA00GI15 issued on 8/10/00
^ Oil level setting Bulletin 44/01/99/NAS (NO dipstick)
^ Oil level setting Bulletin 44/01/98/NAS (WITH dipstick)
2. Fault reference #1: If transmission slips on 2-3 or 3-4 shift (or both), and/or slips when a kick-down shift (or "passing gear" is called for) 4-3
or 3-2 is tried, check oil level and record results on ATER.
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NOTE:
It is possible that no fault codes have been logged even though the slip may be severe (although a downshift over-speed fault code may be
logged).
3. Test vehicle to verify complaint and to ensure problem is repeatable as follows:
^ If complaint relates to the 3-4 shift for example, drive the car in position D3 and confirm shifts 1-2, 2-3 are OK
^ Stop the vehicle and accelerate from rest in position D3
^ At 40-50 mph shift lever into position D
^ If engine revs increase or "flares" as the shift to 4th is made on a repeatable basis the fault is internal to the transmission
4. If the oil level is correct (or fault persists after oil level correction) AND the fault is repeatable in nature replace transmission and flush oil
cooler lines.
5. Ensure ATER is completed, record fault reference # 1 on ATER and fax to HelpLine.
INVESTIGATE ALL VEHICLES PRIOR TO MY2001:
LOSS OF DRIVE OR SLIPPING - FAULT REFERENCE # 2 & # 3 & # 4
1. Determine the validity of the customer complaint:
^ Loss of forward drive
^ Loss of drive, forward and reverse
^ Loss of drive forward and reverse as car warms up
^ Slipping in drive
^ Slipping in drive and reverse
NOTE:
The loss of forward drive symptoms suggest that the "A" clutch (main forward clutch) has failed. This clutch is not used in reverse. As a
result reverse gear engages and operates as normal.
CAUTION:
Oil levels must be checked COLD with engine running. Refer to TIBs 44/01/99/NAS and 44/01/98/NAS as well as Service Alert
SA0015GI-15 for additional guidance.
2. Fault reference #2: If loss of all forward drive is encountered but reverse gear operates correctly perform the following:
^ Verify correct oil level. If the transmission oil level is set/filled incorrectly (too low) or if oil is lost as in the case of a severe leak from the
transmission or cooler/cooler lines this fault may result.
^ On electronic transmissions the stall speed monitoring fault should be recorded in the transmission fault memory (P0722, Bosch, 27
GEMS).
^ It is possible that the oil looks or smells burnt.
3. If the fault is still present after checking/correction of oil level AND the fault occurs every time acceleration from rest is attempted, replace
transmission and flush oil cooler lines.
4. Ensure ATER is completed, record fault reference # 2 on ATER and fax to the HelpLine along with TestBook fault code print outs detailing
fault codes recorded.
NOTE:
The loss of drive in positions "D", "D3" or "D2" failure symptoms suggest that the first speed freewheel has failed. This can occur if "D"
is engaged while the car is rolling backwards causing overload of the freewheel and subsequent failure. Transfer box chain slip can also
cause this fault by providing shock loads to the transmission. In positions "D", "D3" & "D2" the freewheel holds the torque when
accelerating from rest. In position "D1"the freewheel is supported by engagement of a clutch (to provide engine braking). This will "lock"
the freewheel even if it has failed, allowing the car to pull away normally.
CAUTION:
Oil levels must be checked COLD with engine running. Refer to TIBs 44/01/99/NAS and 44/01/98/NAS as well as Service Alert
SA0015GI-15 for additional guidance.
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5. Fault reference #3: If loss of drive in positions "D", "D3" or D2" is determined but the vehicle drives when in "D1" or when reverse gears
engaged, perform the following:
^ On electronic transmissions the stall speed monitoring fault code should be recorded in the fault memory (P0722, Bosch, 27 GEMS).
^ The oil may look clean and smell normal with this fault.
^ Check oil level and record results on ATER.
6. If the fault is still present after checking/correction of oil level AND the fault occurs every time acceleration from rest is attempted, replace
transmission and flush oil cooler lines.
7. Ensure ATER is completed, record fault reference # 3 on ATER and fax to the HelpLine along with TestBook fault code print outs detailing
fault codes recorded.
NOTE:
The symptoms of no drive in forward or reverse indicate a serious internal transmission failure BUT could also be a failure of a component
outside of the transmission, for example transfer box failure. Where an internal transmission failure exists there should be a stall speed
monitoring fault code stored (electronic transmissions only).
CAUTION:
Oil levels must be checked COLD with engine running. Refer to TIBs 44/01/99/NAS and 44/01/98/NAS as well as Service Alert
SA0015GI-15 for additional guidance.
8. Fault reference # 4: If vehicle has no drive at all forward or reverse, check the oil level and record results on ATER.
^ If the transmission has just been fitted to the car as a result of a transmission replacement or engine repairs, the oil pump drive dogs may
have been broken off during installation. Contact the HelpLine for assistance.
^ If the transmission has just been serviced, oil changed or the oil and filter changed, verify oil level and ensure that the filter and O-ring are
installed correctly. Contact the HelpLine for assistance.
^ If the transmission controller DOES NOT have the stall speed fault code logged (P0722 - Bosch 27 GEMS), the failure may not be the
transmission. Contact the HelpLine for assistance.
9. If the fault is still present after checking and correction of oil level AND the fault occurs every time acceleration from rest is attempted AND
the stall speed fault code is logged (P0722 - Bosch, 27 GEMS), replace transmission and flush oil cooler lines.
10. Ensure ATER is completed, record fault reference # 4 on ATER and fax to the HelpLine along with TestBook fault code print outs detailing
fault codes recorded.
INVESTIGATE DISCOVERY II, RANGE ROVER 4.0 & 4.6:
FAULT CODE P0734 (BOSCH), 43 (GEMS) FAULT REFERENCE #5
NOTE:
This fault code indicates that the diagnostics saw a difference between the transmission input speed and the transmission output speed that
exceeded the permissible 4th gear ratio. This could be a result of actual slip or an incorrect input/output speed signal. The output speed signal is
read from the auto transmission output speed sensor in the transmission. The input speed signal is a theoretical value (there is no input speed
sensor in the auto transmission) calculated from the engine torque/speed signals from the EMS.
CAUTION:
Oil levels must be checked COLD with engine running. Refer to TIBs 44/01/99/NAS and 44/01/98/NAS as well as Service Alert SA0015GI-15
for additional guidance.
1. If the transmission has been serviced recently, investigate the oil level. Incorrect levels can lead to this fault code being logged.
2. Check the condition of the transmission oil for evidence of water contamination.
3. Inspect fluid to determine if it is black/burnt.
4. Determine if the oil smells burnt.
5. If there is any doubt about the oil condition, remove the oil pan and inspect and call the HelpLine for further assistance.
6. If there are no obvious signs of transmission slip or malfunction, road test the car to confirm that the transmission operates as expected.
NOTE:
There may be engine fault codes logged as well as this transmission fault code. Typically the codes are P0171, P0174. Correcting the
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cause of these faults will prevent further occurrences of the transmission code. However, it has also become clear that a mass air flow
meter can provoke this transmission code without recording any engine fault codes. Follow LR diagnosis procedure for Mass air flow
meter.
7. If all of the following conditions exist:
^ The oil level is correct
^ The oil condition was found to be normal
^ The transmission operated correctly on road test
investigate engine mass air flow meter for faults. DO NOT REPLACE TRANSMISSION
8. Ensure ATER is completed, record fault reference # 5 on ATER and fax to HelpLine at along with TestBook fault code print outs detailing
fault codes recorded.
INVESTIGATE DISCOVERY II, RANGE ROVER 4.0 & 4.6 TO 1999:
FAULT CODES P0501, P1884 AND P0722 FAULT REFERENCE #6
NOTE:
The customer will probably report that the fault occurred after starting the car from cold and could also report that the car has no power, is
running rough or misfiring. With the fault codes cleared the car should run fine. This fault can occur if the driver engages drive and applies
throttle immediately after start up. This can lead to the stall speed diagnostics being "tripped" as the engine speed exceeds the upper diagnostic
threshold. The software for the stall speed diagnostics has been altered from 00MY to prevent these codes from being recorded in error.
1. Determine which of the following symptoms exist:
^ Vehicle runs rough and has no power
^ Transmission fault lights/message displayed
^ Fault codes P0501 (in Bosch controller) AND P0722 & P1884 in transmission controller are set
^ When the fault codes are cleared car appears to operate normally
^ Customer states that the fault occurs only after starting from cold
CAUTION:
These codes can be caused by other issues and logged separately. In such cases contact the HelpLine for further assistance.
2. Confirm that all three fault codes are recorded:
^ P0501 in engine controller
^ P0722 and P1884 (V3 road speed invalid) in transmission controller
3. Clear the fault codes from both controllers and test drive the vehicle.
4. If further faults are noted during road test or fault codes are re-logged, contact the HelpLine for further assistance.
5. Use TestBook/T4 to verify the Land Rover part number of the transmission controller (ECU).
NOTE:
TestBook/T4 displays the part numbers before fault codes are accessed.
^ Old level software: Series II UHC100240/UHC100360
^ Old level software: Range Rover UHC100220
^ New level software: Series II UHC000010 or UHC00080
^ New level software: Range Rover UHC100340
CAUTION:
Series II transmission ECU's can be plugged in without any further work required. Range Rover transmission ECU's need to have the tune
selected (4.0 or 4.6) using TestBook.
6. If all three codes were present AND the car operated correctly after clearing the codes AND the transmission controller ECU contains the
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OLD level software, install the latest level transmission control ECU with new software. DO NOT REPLACE TRANSMISSION.
7. Ensure ATER is completed, record fault reference # 6 on ATER and fax to HelpLine at along with TestBook fault code print outs detailing
fault codes recorded.
Land Rover Range Rover Technical Service Bulletin # D2332 Date: 051029
Recall - A/T Fluid Water Contamination
No: D233
Ref:
*Issue: 2
Date: 29 October 2005*
Recall:
AT Breather Repositioning and Fluid
Check
AFFECTED VEHICLE RANGE:
Range Rover (LP) XA400939 to 1A452817 Bosch EMS equipped
Discovery Series II (LT) XA220000 to 1A299999
1A700000 to 1A713517517
Updated information is shown by asterisks and shaded areas.
SITUATION:
TRANSMISSION WATER INGRESS THROUGH BREATHER
Condensation from Air Conditioning and water from a "deep wading" event can flow over the transmission and collect on the transmission breather
tube on Range Rover and Discovery Series II vehicles. It can then migrate up the transmission tube. Over time these small water droplets can
cause an accumulation of water in the transmission causing problems associated with water contamination harsh gear changes, poor gear selection,
gear slip or loss of drive and intermittent failure of the park lock function.
RESOLUTION:
NOTE:
This procedure is complicated. Reading and understanding all of the Option steps is important before undertaking any repairs.
REPOSITION BREATHER TUBE AND INSPECT FLUID
Re-route the breather tube to the top of the transmission to eliminate the breather tube as a source of transmission contamination. Test the park lock
feature of the transmission and then determine if the AT fluid is contaminated by a fluid inspection. Carefully follow the corrective steps to ensure
proper operation of the transmission park lock function and removal of any water contamination.
PARTS INFORMATION:
NOTE:
Only a small portion of vehicles covered by this Recall are expected to require repair parts. (Approximately 1%).
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WARRANTY CLAIMS:
Normal warranty policy and procedures apply
Repair Procedure
PERFORM VERIFICATION OF BREATHER LOCATION ON DISCOVERY SERIES II
NOTE:
A precise VIN for Discovery Series II vehicles is not available for the change of breather tubes from the engine bay "shepherds crook" design to
the transmission sump-mounted version rerouted by this Recall. A quick visual check should be undertaken on all vehicles to ensure that the
Recall applies to the existing vehicle configuration.
1. Inspect under Discovery Series II vehicle to verify that transmission mounted breather pipe is present.
2. If no breather pipe is observed, open the hood and inspect for presence of two "shepherd's crook" design breathers (Transmission and Transfer
Gearbox) along engine bulkhead behind the RH side of the engine. (Figure 1)
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3. If shepherd's crook breathers for both the transmission and the transfer gearbox are present, perform the following:
^ Go to "Campaign Label Installation" and install a label for D233
^ Claim Recall D233 Option 1
POSITION BREATHER TUBE NEW VEHICLES IN RETAILER INVENTORY
UNDER 500 MILES AND NEVER WADED
1. Raise vehicle on lift.
2. Locate end of transmission breather tube clipped to the edge of the transmission pan. (Figure 1)
3. Inspect the end of the tube for blockage or damage.
4. Unfasten clip from transmission and remove the clip from the tube. Discard the clip.
5. Guide the end of the breather tube up over the top of the transmission housing.
6. Locate the white three-hole tube-locating clip near the top of the transmission housing.
7. Spray a small amount of silicon lubricant on the breather tubing near the locating clip.
CAUTION:
The orientation of the breather pipes is slightly different on Range Rover and Discovery Series II vehicles. On Discovery Series II vehicles
observe the following:
^ The Transfer Gearbox breather and the Transmission breather come from opposite sides of the vehicle. Movement of the white tube locating
clip is limited by the divergence of the tubes.
^ The breather is secured to an electrical harness and must be released from that restraint.
^ Care must be exercised to avoid crimping or deforming the tubing.
8. On Range Rover vehicles slide the white tube clip toward the rear of the vehicle until it stops against the bulge at the end of the repositioned
drain tube. (Figure 2)
9. On Discovery Series II vehicles perform the following:
^ Snip the cable tie to release the breather tube from the electrical harness.
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^ Slide the white tube clip toward the rear of the vehicle until resistance is met because of the divergence of the transmission and transfer
box tubes. (Figure 3)
^ Verify that the end of the breather tube is parallel with the AT breather and pointed toward the LH rear of the vehicle.
10. Wipe any residual silicon lubricant from tubes.
11. Go to "Campaign Label Installation" and install a label for D233
12. Claim Recall D233 Option 2
PERFORM PARK LOCK TEST
CAUTION:
Every test must be carried out on a slope selected so that the vehicle will roll slowly forward with the transmission selector in the "N" neutral
position. Ensure that no obstruction or object will interfere with testing.
1. Check the park lock function as follows:
^ Position vehicle on a slight forward down slope.
^ Start the engine, place the transmission in "N" neutral and allow the vehicle to roll forward no more than two meters (6 feet).
^ Stop the vehicle completely using the foot brake and select "P" park.
^ Release the foot brake and check that the vehicle does not roll forward.
^ Repeat this procedure nine more times.
2. If the park lock fails to hold on any of the ten tests, go to "REPLACE TRANSMISSION" section of this TIB.
3. If the park lock holds in all ten tests, go to the "Position Breather Tube and Test Fluid for Contamination" section of this TIB.
REPLACE TRANSMISSION
1. Refer to Service Bulletin SWA00-06. Contact ZF at 201 573 7709 following normal automatic transmission replacement procedures.
2. Remove transmission with park lock failure and install a replacement transmission following the procedures in RAVE, Section 44.20.04.99.
3. Flush transmission cooler and cooler lines prior to installation of the replacement transmission.
4. Route the breather tube during transmission installation as follows:
^ Locate end of transmission breather tube and inspect the end of the tube for blockage or damage.
^ Guide the end of the breather tube up over the top of the transmission housing.
^ Locate the white three-hole tube-locating clip near the top of the transmission housing.
^ Spray a small amount of silicon lubricant on the breather tubing near the locating clip.
CAUTION:
The orientation of the breather pipes is slightly different on Range Rover and Discovery Series II vehicles. On Discovery Series II vehicles
observe the following:
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^ The Transfer Gearbox breather and the Transmission breather come from opposite sides of the vehicle. Movement of the white tube-locating
clip is limited by the divergence of the tubes.
^ The breather is secured to an electrical harness and must be released from that restraint.
^ Care must be exercised to avoid crimping or deforming the tubing.
5. On Range Rover vehicles slide the white tube-locating clip toward the rear of the vehicle until it stops at the end of the repositioned drain tube.
(Figure 2)
6. On Discovery Series II vehicles perform the following:
^ Snip the cable tie to release the breather tube from the electrical harness.
^ Slide the white locating tube clip toward the rear of the vehicle until resistance is met because of the divergence of the transmission and
transfer box tubes. (Figure 3)
^ Verify that the end of the breather tube end is parallel with the outgoing AT breather tube and pointed toward the LH rear of the vehicle.
7. Wipe any residual silicon lubricant from tubes.
8. Go to "Campaign Label Installation" and install the label.
9. Claim Recall D233 Option 5, 6, or 7 depending on the vehicle serviced.
POSITION BREATHER TUBE AND TEST FLUID FOR CONTAMINATION
1. If the park lock holds in all ten tests, raise vehicle on lift.
2. Locate end of transmission breather tube clipped to the edge of the transmission pan. (Figure 4)
3. Inspect the end of the tube for blockage or damage.
4. Unfasten clip from transmission.
5. Guide the end of the breather tube up over the top of the transmission housing.
6. Locate the white three-hole tube-locating clip near the top of the transmission housing.
7. Spray a small amount of silicon lubricant on the breather tubing near the locating clip.
CAUTION:
The orientation of the breather pipes is slightly different on Range Rover and Discovery Series II vehicles. On Discovery Series II vehicles
observe the following:
^ The Transfer Gearbox breather and the Transmission breather come from opposite sides of the vehicle. Movement of the white
tube-locating clip is limited by the divergence of the tubes.
^ The breather is secured to an electrical harness and must be released from that restraint.
^ Care must be exercised to avoid crimping or deforming the tubing.
8. On Range Rover vehicles slide the white locating tube clip toward the rear of the vehicle until it stops against the bulge at the end of the
repositioned drain tube. (Figure 1)
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9. On Discovery Series II vehicles perform the following:
^ Snip the cable tie to release the breather tube from the electrical harness.
^ Slide the white locating tube clip toward the rear of the vehicle until resistance is met because of the divergence of the transmission and
transfer box tubes. (Figure 2)
^ Verify that the end of the breather tube is parallel with the outgoing AT breather and pointed toward the LH rear of the vehicle.
10. Wipe any residual silicon lubricant from tubes.
NOTE:
The fluid testing process must be followed carefully to avoid unnecessary loss of AT fluid. Done with care and with the proper tools,
approximately 100 cc (3-4 oz.) of fluid can be drained for evaluation. You must have approximately two inches of fluid in the bottom of your
container when the fluid sample is taken.
WARNING:
Fluid drained from the sump pan may be "hot". Exercise care when draining the fluid.
11. Test the fluid to determine the presence of water contamination as follows:
^ Obtain a clean, clear glass container about three inches in diameter and about 6 inches tall.
^ Using a 5 mm Allen wrench, break the seal on the transmission drain plug.
^ Orient the Allen wrench with the long portion vertical and carefully unscrew the plug until AT fluid seepage is observed.
^ Hold the container under the plug opening and carefully unscrew the plug until no threads are engaged but maintaining pressure against the
opening.
^ Tilt the plug slightly to drain the fluid sample required to give 1.5 to 2 inches of fluid in the bottom of the container.
^ Thread the plug back into the opening reusing the original seal.
Torque the plug to 15 Nm (11 lbf.ft.).
NOTE:
If a level of uncertainty exists as to the correct appearance of the sample, a comparison of the sample taken to new fluid from stock will be
helpful.
12. Visually inspect the fluid for the presence of water contamination against the following parameters:
Uncontaminated fluid will have a bright red appearance and will be "clear". You can easily see your finger on the bottom of the clear container
from the top through the 2 inches of drawn fluid.
^ Lightly contaminated fluid will have a deep burgundy red color and cloudy appearance.
^ Heavily contaminated fluid will have a "milky pink" appearance.
13. If the transmission fluid is clear, perform the following:
Top up the transmission fluid level to the correct level making sure to follow the procedure outlined in TIB 44/01/99/NAS.
Install the campaign label as outlined in the "Campaign Label Installation" section of this TIB.
^ Claim Recall Option 3.
14. If the transmission fluid exhibits a contaminated appearance, drain and flush the transmission using the method specified in the next section.
DRAIN AND FLUSH TRANSMISSION
WARNING:
Fluid drained from the sump pan may be "hot." Exercise care when draining the fluid.
NOTE:
Fluid will remain in the torque converter, therefore only 5 liters of fluid can be drained at any one time.
1. Drain the fluid from the transmission.
2. Remove the oil pan and strainer.
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3. Clean out all debris and sludge from the pan using a lint free cloth.
4. Refit old strainer and pan using the original seal.
CAUTION:
Additional fluid will need to be added to the transmission after the engine has been started to bring the fluid to approximately the correct level.
WARNING:
Ensure wheel chocks are set during the following procedure and hand brake and foot brake are applied when selecting gears.
5. Fill the transmission with new fluid.
6. Carry out the flushing process as follows:
^ Start and run the engine.
^ Select all gears twice and then select neutral "N" position.
^ Add fluid as described in TIB 44/01/99/NAS to obtain proper fluid level.
^ Run the engine for 20 minutes
^ Switch off engine.
WARNING:
Fluid drained from the sump pan may be "hot." Exercise care when draining the fluid.
7. Check the water content of the transmission fluid again as described in "Position Breather Tube and Test Fluid for Contamination."
8. If the fluid is still contaminated go to Step 1 of this section and flush as many times as required until the fluid is clear.
9. When the fluid checked is clear, perform the following:
^ Drain the fluid from the transmission.
^ Remove the sump pan and discard the pan seal.
^ Remove the strainer and discard.
^ Wipe out the sump pan with a lint free cloth to remove any residual debris and sludge.
^ Fit new strainer with O-ring and tighten retaining screws to 8 Nm (71 lbf.in.).
^ Install new sump pan seal.
^ Install the pan to the transmission and tighten fasteners to 8 Nm (71 lbf.in.).
10. Fill the transmission with the correct quantity of fluid up to the level plug.
11. Start and run the engine.
12. Check fluid level as described in TIB 44/01/99/NAS to obtain proper fluid level.
13. Road test the vehicle to verify that the transmission functions correctly.
14. Install the campaign label as outlined in the "Campaign Label Installation" section and claim Recall Option 4.
CAMPAIGN LABEL INSTALLATION
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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:
^ Campaign code performed ("D233")
^ Your Retailer code
^ The date of repair
2. Peel the label back, apply to radiator support and roll the label with the special roller.Land Rover Range Rover Technical Service Bulletin # TEC440100Date:
000324
A/T - Flex Plate Spacer Specifications
No: 44/01/00/NAS
Ref: 44/03/95/US
Issue: 1
Date: 03/24/00
Flex Plate Spacer Specifications
AFFECTED VEHICLE RANGE:
Range Rover (LP) All
SITUATION:
FLEX PLATE SPACER RING SPECIFICATION FOR 4.0/4.6
It is possible to inadvertently install incorrect specification spacer rings with the twin flex-plate system used in Range Rover vehicles.
RESOLUTION:
CORRECT SPACER USE AND THICKNESS SPECIFICATION
To ensure that the correct spacer is fitted to a vehicle under repair, refer to the application table and to the Parts Information section for the correct
thickness notations for each application.
PARTS INFORMATION:
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FTC4608 Flex-Plate Spacer Qty 1 (12 mm thick) All GEMS 4.0
FTC4609 Flex-Plate Spacer Qty 1 (4 mm thick) All GEMS 4.6
TPE100130 Flex-Plate Spacer Qty 1 (7 mm thick) From XA410482 both 4.0 & 4.6
WARRANTY CLAIMS:
Normal warranty policy and procedures apply
Land Rover Range Rover Technical Service Bulletin # NHTSA00V142001 Date: 001013
Recall 00V142001: Serpentine Belt Pulley Failure
The loading conditions on the vehicle's left side engine idler pulley can exceed the maximum calculated figure of the original design specification.
The material of the pulley can fracture and ultimately fail. Failure of the pulley material can cause the pulley to throw off the serpentine belt.
This could result in a loss of engine auxiliary functions (power steering, water pump, alternator, air conditioning and ACE).
Dealers will install an improved idler pulley.
Land Rover has not yet provided an owner notification schedule for this portion of the recall. Owners who take their vehicles to an authorized dealer
on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Land Rover at 1-800-637-6837. Also
contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).Technical Service
Bulletin # TEC860804 Date: 041220
Antitheft System - False Alarm/'Bonnet Open' Message
No: 86/08/04/NAS
FGN LM419
Ref:
Issue: 1
Date: 20 December 2004
Hood Alarm Switch Sensitivity
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
SITUATION:
FALSE ALARM ACTIVATION AND/OR "BONNET OPEN" MESSAGE DISPLAYED
Build tolerances in the hood and hood switch can allow the switch contacts to close. This causes the alarm to see a hood-open condition that in turn
activates the vehicle security alarm. The customer may also see a "bonnet open" message displayed on the message center.
RESOLUTION:
INVESTIGATE HOOD SWITCH FUNCTION
Should a customer complain of unexplained alarm messages or activation, follow the procedure in this TIB to confirm that the hood switch triggered
the alarm activation. If indicated replace the switch.
PARTS INFORMATION:
DDW WARRANTY CLAIMS:
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DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
INVESTIGATE ALARM TRIGGER CAUSE AND REPLACE SWITCH IF INDICATED
NOTE:
The battery must be capable of maintaining a full charge during this process which is expected to take 15-18 minutes total.
1. Verify the battery is fully charged (12.6 V or greater).
2. Connect a battery charger set on a low amp current charge to maintain battery state during this process.
3. Connect 14 to the vehicle and load disc "Range Rover 14" or a later version.
4. Begin a new diagnostic session.
NOTE:
For each alarm trigger the following data is displayed:
^ Alarm trigger ID - this is the alarm trigger ID for the alarm displayed on the screen
^ Alarm description - this describes which part of the vehicle triggered this alarm
^ Alarm code - this is the alarm trigger code
^ Alarm frequency - this is the number of times the relevant alarm has been triggered
^ Alarm present - this displays whether it is an old trigger or the last alarm triggered
5. Following all of the on-screen instructions perform the following:
^ Select "System Diagnostics".
^ Select "Security".
^ Select "Vehicle Maintenance".
^ Select "Alarm Trigger History".
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LM - New Range Rover/2005 > Workshop Manual - Service Procedures > "Alarm System and Horn"
> "Repairs" > "Switch - bonnet" link
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6. If a fault code is stored identifying that the hood (bonnet) switch triggered the alarm, refer to GTR Workshop Manual section 86.77.20 and
replace the switch with a new specification switch (YUE000162).
7. If there is no fault code stored identifying that the hood switch triggered the alarm, perform further investigation as required.
8. When repairs are completed, reset the alarm trigger history.
9. End the diagnostic session and return to the "Welcome" screen.
10. Disconnect 14 and the battery charger from the vehicle.Land Rover Range Rover Technical Service Bulletin # TEC820103 Date: 040227
A/C - 'Handbook Symbol' Displayed on ATC Display
No: 82/01/03/NAS
Ref:
Issue: 1
Date: 27 February 2004
Automatic Temperature Control Fault
Display Correction
AFFECTED VEHICLE RANGE:
Range Rover (LP)
up to 2A427128
SITUATION:
HANDBOOK SYMBOL ILLUMINATED ON THE ATC DISPLAY
When the coolant temperature reaches 97°C (207°F) and stays at or above that temperature for ten minutes, the Automatic Temperature Control
(ATC) diagnostic system will illuminate the handbook symbol on the ATC display. The diagnostic fault code in the ATC panel software is set too
low for normal vehicle operating conditions in very hot climates.
RESOLUTION:
INSTALL RESISTOR TO ADJUST ATC INPUT
NOTE:
Installation of the resistor will "adjust" the displayed output temperature seen in real-time T4 monitoring. Comparing the ATC sensor output
after the modification with other coolant temperature information in real time can be misleading.
CAUTION:
It is important to verify that there is not a mechanical cause for high coolant temperatures. Inspections for leaks and verification of the coolant
level as well as proper fan and thermostat operation should all be verified.
Should a customer express concern regarding the appearance of the handbook symbol during hot weather operation, the DTCs should be examined
to determine if the vehicle has a fault for the heater core temperature sensor. If that fault is flagged on vehicles built before the above VIN, follow
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the rectification procedure in this TIB to install an in-line resistor link lead between the heater temperature sensor and the electrical harness.
Also refer to TIB 80/03/96/US for information relating to intermittent operation of early vehicle heater core sensors. Sensor date codes should be
(April 1996) or higher.
PARTS INFORMATION:
YMQ501010 Link lead Qty 1
AS400 WARRANTY CLAIMS (CANADA ONLY)
82.20.94 Time 0.10 hrs.
Install ATC system wiring resistor link lead
FAULT CODE: A
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply. Material allowance is included in labor operation.
REPAIR PROCEDURE
INSTALL LINK LEAD RESISTOR
1. Refer to RAVE Workshop Manual section 82.20.94 and perform steps 1-5 to gain access to the heater temperature sensor.
2. Disconnect the heater temperature sensor multi-plug. (Arrowed in Figure 1).
3. Connect the link lead MQ501010) to the heater temperature sensor and electrical harness (Figure 2).
4. Reverse the Workshop Manual section 82.20.94 removal procedures steps 1-5, and install the removed components.Technical Service
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Bulletin # TEC820504 Date: 041220
A/C - Scraping Noise From Control Panel
No: 82/05/04/NAS
FGN LM412
Ref:
Issue: 1
Date: 20 December 2004
Heater Control Panel Fan Noise
AFFECTED VEHICLE RANGE:
New Range Rover (LM) Up to 4A164860
SITUATION:
NOISE COMING FROM CONTROL PANEL AREA
A customer may report a concern of a noise/scraping sound from the Heating, Ventilation and Air Conditioning (HVAC) control panel in the dash.
The aspirator fan, located inside the control panel, can be out of tolerance and run off-center resulting in contact with the casing.
RESOLUTION:
INVESTIGATE SOURCE OF NOISE AN REPAIR
Should a customer express concern regarding the above, the control panel should be replaced. Refer to the Service Procedure detailed in this
Bulletin.
PARTS INFORMATION:
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
REPLACE HVAC CONTROL UNIT
1. Verify the symptoms.
NOTE:
GTR lookup sequence is as follows:
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GTR Home > NAS > Service Information/ LM New Range Rover/2004 > Workshop Manuals > Service Procedures> Bookmark "Heating
and Ventilation" > "Repairs" > "Controls - heater (ECU)" link
2. Refer to GTR Workshop Manual section 80.10.02 and remove the HVAC control unit.
3. Note the control unit part number from the label and determine that the production date code is "E11" or lower. (Figure 1)
4. If the production date code is "E11" or lower, install a new unit of the correct replacement part number with a date code of "E12" or higher.
NOTE:
The battery must be capable of maintaining a full charge during the T4 programming process.
5. Verify the battery is fully charged (12.5v or greater).
6. Connect a battery charger set on a low amp current charge to maintain battery state during this process.
7. Connect 14 to the vehicle and start a diagnostic session.
8. Using 14 and Range Rover 14 disc or higher, observe all of the on-screen instructions presented and perform the following steps:
^ On the 14 Main Menu select "System Diagnostics - Air Conditioning."
^ Select "Vehicle Maintenance."
^ Select "ECU Replacement." And follow on-screen instructions.
9. When the software download is complete, disconnect the battery charger and T4.
10. Verify proper operation of the HVAC control unit.Land Rover Range Rover Technical Service Bulletin # TEC190198 Date: 990730
Ignition System - Hard Start/Rough Running/Misfire Codes
No.: 19/01/98/NAS
Ref: TIB 19/07/96/US
Issue: 4
Date: 07/30/99
High-tension Ignition Lead Check
AFFECTED VEHICLE RANGE:
VEHICLES EQUIPPED WITH 14 CUX OR GEMS ENGINE MANAGEMENT SYSTEMS
SITUATION:
ASSISTANCE IN IGNITION RELATED DIAGNOSTICS
The information provided in this document is intended to assist in diagnosing ignition lead faults and summarizes ignition related issues previously
issued as part of Operation Pride.
171
RESOLUTION:
DIAGNOSE AND IF INDICATED REPLACE INDIVIDUAL FAULTY IGNITION LEADS
NOTE:
Ignition faults are only one cause of the symptoms described in this TIB. Investigation of other causes may need to be explored to determine the
root cause of the customer complaint.
When you suspect an ignition lead fault is the cause of customer complaints relating to hard starting, rough running or OBD misfire faults, the
procedures in this document are provided to assist diagnosis and repairs. Only ignition leads determined to be faulty are to be replaced.
PARTS INFORMATION
WARRANTY CLAIMS:
Normal warranty policy and procedures apply.
Complete wire sets replaced due to faulty individual leads will not be paid by warranty.
Claims for damaged non-defective leads will be subject to debit.
REPAIR PROCEDURE:
14CUX IGNITION SYSTEM PHYSICAL AND RESISTANCE CHECKS
CAUTION:
Always use correct procedures when removing ignitions leads to avoid damage to the lead. Testing may be required to verify lead
condition.
1. Install coil primary eyelet connectors as described in TIB 19/07/96/US.
NOTE:
Surface cracks in any engine lacquer sprayed on the wires should be ignored, but any wire that is obviously damaged should be replaced.
2. Inspect secondary ignition wires visually for damage to cables or boots.
CAUTION:
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Always verify that ignition cable terminals at all locations are fully engaged.
3. Ensure that the wire connectors are fully engaged with the terminals on the spark plugs, distributor and coil.
4. If any connectors are found to be loose, the wire terminal, boot and mating half connector should be cleaned with brake cleaner and inspected:
^ If serious corrosion or damage is evident, replace the wire.
^ If no serious corrosion or damage is evident, ensure the mating connections are clean and assembled.
5. Attach TestBook with Bear Engine Analyzer to the vehicle and connect for conventional ignition as follows:
^ Attach yellow lead to coil wire.
^ Plug the yellow lead into the spot where the eight lead for plug wires on Direct Ignition attach.
^ Attach the green trigger lead to the # 1 plug wire.
^ Attach the small wire with the black clip (connected to the battery leads) to the negative terminal of the ignition coil.
^ Connect the high voltage pickup and trigger pickup around ignition wires which have been cleaned for 75 mm (3 inches) in either direction
of the pickup with brake cleaner.
6. Perform the secondary ignition test and verify that the results are within the following limits:
^ Average Kv 12-17KV
^ Snap KV 17-26KV
^ Burn Time 0.4-2.0
NOTE:
Other faults, such as fueling faults may give unusual readings.
7. If any of these readings are abnormal, check the following:
^ Ensure that base time is set to the Workshop Manual specification.
^ Verify condition and gap of spark plugs.
^ Inspect condition of distributor cap and rotor (cracks, dirt, carbon brush condition).
^ Check resistance of spark plug and coil wires. Resistance should be between 98 and 213 ohms per cm (3 and 6.5 K ohms per foot).
NOTE:
A high average KV, somewhere around 35 KV (see Chart 1), is an indication of an open circuit on that cylinder.
8. Check for variables that raise average KV such as:
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^ High resistance plug or coil wire
^ Connector pulled off plug distributor or coil
^ Carbon brush missing or broken in distributor cap
^ Badly worn spark plug
^ Snap throttle opening
^ Lean Mixture
^ Retarded ignition timing
NOTE:
A very low average KV, around 2-3 KV (see Chart 2) indicates a possible short circuit in the plug wire or spark plug. Only the wires that
are out of specification or show signs of arcing are to be replaced.
9. Check for short circuit in the plug wire or ground electrode contacting center electrode of the spark plug.
10. Check for variables that lower average KV such as:
^ Grounded or fouled plug
^ Small plug gap
^ Rich Mixture
^ Advanced timing
^ Poor Compression (burned valves for example)
11. If there is no sign of misfire, the wires should be considered serviceable.
CAUTION:
Do not spray the wires with water. In the past, this has been the recommended procedure. This diagnostic technique can, however, be
misleading. Spraying water precipitates a condition called "corona discharge." Corona discharge is a low voltage spark (outside the lead)
which has the same appearance as arcing, but which does not affect the firing of the cylinder. Observing a corona discharge display can
lead to misdiagnosis and unnecessary replacement of high-tension leads.
12. If a misfire is evident and no high-tension lead fault is found, investigate the following causes:
^ Fueling and Injectors
^ Compression
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^ Spark plugs
^ Distributor cap and rotor
^ Ignition coil
^ Crankshaft sensor
^ Exhaust leak
^ Exhaust valve sticking
^ Worn camshaft
GEMS IGNITION SYSTEM PHYSICAL AND RESISTANCE CHECKS
1. Check spark plug wires for damage or looseness.
2. Check all primary circuit wires for tightness, damage or corrosion.
3. Replace any damaged components.
4. Remove spark plugs, ensure plug gap is correct and check for fouling.
NOTE:
Check ignition wire resistance first by measuring the entire length of a companion wire set from one plug end of the wire set to the other
plug end through the coil.
5. Verify that a resistance between 24-40 K ohms is obtained when measuring from plug end to plug end with the leads attached to the coil.
6. If out of specification, measure coil and wires separately.
^ Coil secondary resistance should be 13 K ohms.
^ Spark plug wire resistance should be 98 to 213 ohms per cm (3 to 6.5 K ohms per foot) measured from coil end to plug end of the wire.
7. Replace any damaged components.
BEAR ANALYZER IGNITION TEST CONNECTION FOR GEMS IGNITION SYSTEM
1. Attach TestBook with Bear Engine Analyzer to the vehicle and connect for Direct Ignition System
^ Attach the four red leads to the right plug wires (even numbers).
^ Attach the four black leads to the left plug wires (odd numbers).
^ Attach the green trigger wire to the # 1 plug wire.
2. Perform the secondary ignition test.
Acceptable ranges for secondary testing are as shown.
NOTE:
Other faults, such as fueling faults may give unusual readings.
3. If any of these readings are abnormal, check the following:
^ Verify condition and gap of spark plugs.
^ Verify resistance of spark plug and coil wires is between 3 and 6.5 K ohms per foot.
NOTE:
A high average KV, somewhere around 3.5 KV, is an indication of an open circuit on that cylinder.
175
4. Check for variables that raise average KV such as:
^ High resistance plug or coil wire
^ Connector pulled off plug or coil
^ Badly worn spark plug
^ Snap throttle opening
^ Lean Mixture
^ Retarded ignition timing
NOTE:
A very low average KV, around 2-3 KV indicates a possible short circuit in the plug wire or spark plug. Any wires that are out of
specification must be replaced.
5. Check for short circuit in the plug wire or ground electrode contacting center electrode of the spark plug.
6. Check for variables that lower average KV such as:
^ Grounded or fouled plug
^ Small plug gap
^ Rich Mixture
^ Advanced timing
^ Poor Compression (burned valves for example)
7. If there is no sign of misfire, the wires should be considered serviceable.
CAUTION:
Do not spray the wires with water. In the past, this has been the recommended procedure. This diagnostic technique can, however, be
misleading. Spraying water precipitates a condition called "corona discharge." Corona discharge is a low voltage spark (outside the lead)
which has the same appearance as arcing, but which does not affect the firing of the cylinder. Observing a corona discharge display can
lead to misdiagnosis and unnecessary replacement of high-tension leads.
8. If a misfire is evident and no high-tension lead fault is found, investigate the following causes:
^ Fueling and Injectors
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^ Compression
^ Spark plugs
^ Ignition coil
^ Crankshaft sensor
^ Exhaust leak
^ Exhaust valve sticking
^ Worn camshaft
Land Rover Range Rover Technical Service Bulletin # TA0086012 Date: 000306
Starting System - Intermittent Failure to Start
TA00 8601 *Ed. 2*
March 6, 2000
ATTENTION:
Service Manager
Service Advisor
Technician
Updated information is shown by asterisks.
Loose Electrical Connector at Starter Motor
A number of retailers have encountered 1999 and 2000 MY Bosch EMS-equipped vehicles which fail to start or start intermittently.
Field reports have indicated that the primary electrical connection on these vehicles may not be adequately torqued to provide a solid electrical
connection. Testing of warranty return starters supports the suggestion of a loose connection. Returned starters frequently test "no-fault-found".
Whenever a no-start situation is encountered on 1999 and 2000 "Bosch" Range Rover or Discovery vehicles, the first check should be to tighten the
main starter electrical cable connection as follows:
1. First disconnect battery ground terminal.
2. Slacken and remove the battery-lead-to-starter-solenoid-securing nut.
3. Install a star washer on the solenoid stud.
4. Install and tighten the nut to 18 Nm (13 lb.ft.).
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Replacement of the starter motor is not warranted unless the electrical connection is properly tightened and the no-start condition is determined to
still exist.
* WARRANTY CLAIMS:
86.60.89127 Time 0.20 hrs.
Tighten starter cable
FAULT CODE: S*
Normal warranty policy and procedures apply
Land Rover Range Rover Technical Service Bulletin # TEC120102 Date: 021011
Engine - Oil Leaks From Rear of Engine
No: 12/01/02/NAS
Replaces 12/01/01/NAS
Ref: 12/02/02/NAS
Issue: 1
Date: 10/11/02
Sealing Cam Bore and Galley Plugs
AFFECTED VEHICLE RANGE:
Land Rover V-8
Range Rover (LH) All
Range Rover (LP) All
Discovery (LJ) All
Defender (LD) All
Discovery Series II (LT) All
SITUATION:
OIL LEAKAGE FROM THE CAM BORE AND GALLEY PLUGS
A customer may complain about oil seepage from the rear of the engine. The cam bore plug and cam galley plugs installed with early application
technology may seep engine oil over the life of the vehicle.
RESOLUTION:
SEAL CAM BORE AND CAM GALLEY PLUG WITH LOCTITE(R) PRODUCTS
New sealing processes have been introduced into engine manufacturing that more effectively seal plugs. Seal and install a new cam bore plug where
a leak has been identified or reseal the oil galley plugs if they are the source of the seepage.
PARTS INFORMATION
WARRANTY CLAIMS
Normal warranty policy and procedures apply. Material allowance is included in labor operation.
REPAIR PROCEDURE
SEAL OIL GALLEY PLUGS
178
1. If oil galley plugs have been determined to be the source of the oil leak, remove the old plug using an 8 mm Allen wrench. ("A" in Figure 1)
2. Clean all surfaces to ensure they are free of oil, old sealant and other contamination.
3. Apply Loctite(R) 243 to the threads of a galley plugs.
4. Install plugs and tighten to 55 Nm (40.5 lbf.ft.).
5. Allow Loctite to cure to manufacturer's specification.
SEAL CAM BORE PLUG
6. If cam bore plug has been determined to be the source of the oil leak ("B" in Figure 1), access and remove the old plug as follows:
^ Position a sharp chisel at the center of the plug to maximize clearance to camshaft.
(A" and B" in Figure 2)
^ Pierce the plug
^ Protect the engine block and pry out the old plug.
7. Clean all surfaces to ensure they are free of oil, sealant and other contamination.
8. Apply Loctite(R) 648 to the edges of a new bore plug (602146).
9. Install new plug until the edge of the plug is flush with the block casting ("C" in Figure 2).
10. Allow Loctite to cure to manufacturer's specification.
Land Rover Range Rover Technical Service Bulletin # TEC6002033 Date: 040227
Tires/Wheels - Vibration/Shimmy
No: 60/02/03/NAS
Ref:
179
*Issue: 3*
*Date: 27 February 2004*
Steering/Tire Vibration Correction
AFFECTED VEHICLE RANGE:
New Range Rover (LM)
All
Updated information shown by asterisks.
SITUATION:
VIBRATION FROM WHEELS AND TIRES
A customer may complain of steering vibration or shimmy." Sources of vibration/shimmy can be Radial Force Variation (RFV) in the wheel-tire
assemblies and also the positioning/mounting of the wheels on the vehicle.
RESOLUTION:
MATCH MOUNTING AND WHEEL/TIRE INSTALLATION PROCEDURES
In case of a customer complaint of vibration/shimmy on vehicles, follow the optimization procedures in this bulletin using a Hunter 9700/9712
balancing machine. The procedures to be followed are:
^ Tire to wheel match-mounting
The tire is positioned on the wheel so that the low point of the tire is matched to the high point of the wheel. This procedure is also referred to as
match-mounting. The Hunter 9700/9712 balancing machine performs this procedure.
^ Wheel/tire installation
The wheel/tire assembly is mounted to the vehicle's hub in a manner that allows the Radial Force high point of the assembly to be neutralized by
taking up the inherent clearance in the wheel-to-hub mating surface. The Hunter 9700/9712 balancing machine identifies the high point of the
wheel/tire assembly.
* PARTS INFORMATION *
TOOL INFORMATION:
CAUTION:
Access to a Hunter 9700/9712 wheel-balancing machine is required to perform the steps in this technical bulletin. If this tool is not available onsite,
be sure to bring the required special adapter tools to your local tire store with the Hunter 9700/9712.
180
Land Rover requires that wheel/tire assemblies be mounted to the Hunter 9700/9712 using the correct centering sleeve announced in Bulletin
STEO2-13 and the 5-lug flange plate adaptor previously supplied to Retailers. (Figure 1) This mounting method provides precise balance with
the highest rate of repeatability.
*CAUTION:
Care must be taken to ensure that the balancing location cone / spindle does not contact any part of the wheel/tire assembly except the illustrated
location during the balancing procedure. If the cone contacts any other part of the wheel/tire assembly, an incorrect cone has been selected.
Mounting the Centering Sleeve properly in the wheel opening is vital to the proper location of the wheel on the balance machine. (Figure 2)*
Land Rover recommends the use of a compression tool, such as the HAW 900, to install wheel weights. This tool prevents both accidental
damage to the rim and deformation of the wheel weight clips.
REPAIR PROCEDURE
PREPARATION
NOTE:
Tires are factory "match-mounted" on the wheels by Land Rover at initial assembly. It is important to retain this mounting orientation on
vehicles where it is known that the original factory balance is still intact.
1. Refer to the Owners Handbook specification and inflate tires to proper "cold" air pressures.
NOTE:
Tire heating is REQUIRED. It is extremely vital to the match-mounting process.
2. Drive the vehicle on a 15-20 mile highway-speed road test to ensure that all flat spots are removed and to heat tires to operating temperatures.
3. Lift the vehicle off the ground immediately after the road test to minimize temporary flat spots.
181
4. If tires are directional" tires, mark for installation in the same location on the vehicle after balancing. (Figure 3)
MATCH-MOUNT AND BALANCE
1. If the wheels are known to have non4actory balance or are equipped with new tires, perform the following:
^ Remove wheel assembly while tire is still warm.
^ Measure and record the Radial Force variation.
^ Perform wheel-to-tire match-mounting if balancing machine indicates necessity.
^ Record the amount of the Radial Force variation (lbs.) on the inside of tire with crayon
CAUTION:
For rim-mounted wheel weights, use only Land Rover specification two-piece clip-on wheel weights.
NOTE:
Inner edge of compression tool must be placed close to rim. Outer swivel foot of compression tool must be placed onto shoulder of tire.
^ Balance wheel on the Hunter 9700/9712, installing two-piece weights *(Figure 4)* as follows:
^ Compress the inflated tire at the bead and the shoulder with compression tool.
^ Insert the wheel weight clip between the tire bead and the road wheel. *(Figure 5)*
^ Release the compression tool.
Spread the wheel weight clip using the two-piece Haweka clip tool HAW 900/1.
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^ Slide the weight under the clip. (Figure 6)
^ Verify that the weight is fully seated.
2. If the wheels are known to have the original factory balance intact, perform the following:
^ Remove wheel while still warm.
^ Measure Radial Force variation for wheel, but do not disturb factory wheel weights.
^ Record the amount of the Radial Force variation (lbs.) on the inside of tire with crayon
3. Perform the following steps on wheel/tire assembly:
^ Mark high point spot indicated by Hunter 9700/9712 on the tire with a hash mark on the outer sidewall.
^ Mark the high spot with a permanent white paint mark on the inside sidewall to identify for future repair situations.
4. Verify correct balance for wheel/tire assembly.
5. If the balancer indicates no additional weight is necessary ("0.00g"), loosen the wing nut, gently rock the wheel on the balancer spindle
adapter and tighten wing nut.
6. Verify balance a second time.
7. If the balancer indicates "0.00g", remove the wheel from the machine.
8. If the balancer does not indicate 0.00g perform the following:
^ Add the necessary weight.
^ Verify balance and repeat as required to achiever repeatable "0.00g" readings when the wheel is removed from the balancer
9. Go to Step 1 or Step 2 and perform complete "Match-mount and Balance" steps for each wheel/tire assembly.
MOUNT TIRES TO VEHICLE
1. If vehicle is equipped with directional tires (Figure 1), mount tires in original locations.
NOTE:
On vehicles with directional tires the wheel and tire assemblies can only be optimized at their original location on the vehicle. Step 2 does
NOT apply to directional tires.
2. If vehicle does NOT have directional tires, mount tires in the following locations:
^ Lowest value of Radial Force variation on left front of vehicle
^ Second lowest value of Radial Force variation on right front of vehicle
^ Third lowest value of Radial Force variation on left rear of vehicle
^ Highest value of Radial Force variation on right rear of vehicle.
3. Tighten wheel nuts to a snug "finger tight" condition (no wobble evident between the wheel and mounting surface).
183
4. Rotate each wheel so that the previously marked high point is at the bottom (6 o'clock position) and will contact the floor when the vehicle is
lowered.
5. Lower the vehicle partially to the floor so that light-to-moderate load is placed on each of the wheels.
6. Torque the lug nuts of each wheel to 140 Nm (103 lb/ft.).
7. Road test the vehicle.
Land Rover Range Rover Technical Service Bulletin # TEC760804 Date: 040604
Interior - 'A' Post Trim Creaking Noise
No: 76/08/04/NAS
Ref:
Issue: 1
Date: June 04, 2004
"A" Post Creaking Noise
AFFECTED VEHICLE RANGE:
New Range Rover (LM) Up to
4A163802
SITUATION:
CREAKING NOISE EXPERIENCED DURING CORNERING FROM WINDSHIELD AREA
The 'A' post-upper trim finisher location lug on the fascia can come in contact with the 'A' post-upper trim finisher. A creaking/ticking noise from the
bottom of the 'A' post trim during cornering may result from this contact. The conditions may be more pronounced in cold weather and during the
heater warm-up cycle.
RESOLUTION:
INSERT FOAM CUSHIONING MATERIAL
If a customer should complain of the above symptoms, insertion of a small foam pad under the 'A' post will eliminate the creaking noise.
PARTS INFORMATION:
AMR6507.......Foam pad Qty 1
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
REPAIR PROCEDURE
INSTALL FOAM CUSHIONING
1. Refer to RAVE/GTR Workshop Manual section 76.13.26 and remove the 'A' post-upper trim finisher.
2. Trim the foam pad (AMR6507) to 25 mm X 60 mm (1 inch X 2-3/8 inch).
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3. Install the foam pad to the 'A' post-upper trim finisher location lug. (Figure 1)
4. Install the 'A' post-trim ensuring foam is not displaced.
Land Rover Range Rover Technical Service Bulletin # TEC860601 Date: 010601
Lighting - Side Repeater Lamps Come Loose
No: 86/06/01/NAS
Ref:
Issue: 1
Date: 06/01/01
Side Repeater Lamps
AFFECTED VEHICLE RANGE:
Range Rover (LP) Up to 1A455643
SITUATION:
SIDE REPEATER LAMP ADRIFT FROM FRONT FENDER
Failure of the repeater lamp retaining clip may cause poor retention.
RESOLUTION:
REPLACE LAMP
If a customer complains of poor retention of a side repeater lamp on a vehicle prior to VIN 1A455643, replace the faulty unit with improved part
XGB100280.
PARTS INFORMATION:
XGB100280 Lamp - side repeater (clear lens)
XZQ100210L Bulb - side repeater (amber)
WARRANTY CLAIMS:
86.40.51 Time 0.25 hrs.
Renew one or both side repeater lamps
FAULT CODE: B
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
REPLACE LAMP
NOTE:
Side repeater lights must be the same on both sides of the vehicles. XGB100280 has a clear lens and uses an amber bulb.
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1. Replace defective lamp with new design lamp (XGB100280).
2. Install amber bulb (XZQ100210L).
3. If the replaced lamp has an amber lens, perform the following:
^ Remove the alternate side lamp.
^ Install new style lamp (XGB100280).
^ Install amber bulb (XZQ100210L) in the second new lamp
Land Rover Range Rover Technical Service Bulletin # TEC570405 Date: 050412
Steering - Column Motor Jams During Operation
No: 57/04/05/NAS
FGN LM11
Ref:
Issue: 1
Date: 12 April 2005
Steering Column Reach Motor Jamming
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
SITUATION:
JAMMING OF MECHANISM DURING REACH ADJUSTMENT
NOTE:
Reach mechanism "noise" will generally require reach motor replacement. Refer to TIB 571051051NA5 for guidance on the procedure for reach
mechanism replacement associated with noise.
The customer may complain that during reach adjustment the steering column mechanism occasionally jams or is inoperative.
RESOLUTION:
STEERING REACH MOTOR LUBRICATION
Upon customer complain of the jamming during reach adjustment follow the Repair Procedure outlined in this bulletin to lubricate the reach motor
mechanism.
PARTS INFORMATION:
NOTE:
There is no requirement to replace anything other that the motor bracket to repair an occasional jam condition. The steering column assembly is
not required.
186
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
REMOVE AND REINSTALL REACH MOTOR
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LM Range
Rover/2005 > Workshop Manuals > Service
Procedures > Bookmark "STEERING/REPAIRS" >
link "Column assembly - inner & outer"
1. Refer to GTR Workshop Manual section 57.40.01, and remove the steering column assembly.
2. Release and remove the reach motor from the steering column. (Figure 1)
NOTE:
Broken plastic motor clips may be found upon disassembly or may occur during motor removal. Broken clips will be replaced later in the
procedure.
3. If the plastic motor clip is unbroken, leave it in position.
4. Remove the flexible drive from the steering column.
187
5. Insert the special tool, part number QME500100, into the square drive of the spindle. (Figure 2)
6. Hold the shaft with the tool and release the spindle nut half a turn. (Figure 3)
7. Hold the shaft with the tool and tighten the spindle nut to 6 Nm (4.5 lbf.ft). (Figure 4)
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8. Hold the shaft with the tool and release the spindle nut one "flat." (Figure 5)
9. Remove the tool.
10. If the plastic motor clip is broken, or breaks during motor removal, perform the following:
Remove the broken clip by levering it off. (Figure 6)
CAUTION:
It is critical that the plastic clip is fully engaged into the steering column aluminum body. There will be a loud snapping noise as the clip engages.
^ Align the key on the new plastic motor retaining clip with the machined slot on the aluminum body of the column
^ Snap the new clip into position.
^ Verify that the key is located in the slot and the clip is securely located.
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11. Insert the flexible drive into the spindle. (Figure 7)
12. Slide the motor fully back into the plastic clip, guiding the flexible drive into the gearbox.
13. Verify that the peg locates fully into the motor and that the motor is correctly located in the clip.
(Figure 8)
14. Apply a thin bead of grease onto the tilt and reach spindles.
15. Refer to GTR Workshop Manual section 57.40.01 and install the steering column assembly.
DisclaimerLand Rover Range Rover Technical Service Bulletin # TEC570505 Date: 050412
Steering - Steering Column Reach Motor Noise
No: 57/05/05/NAS
FGN LM211
Ref:
190
Issue: 1
Date: 12 April 2005
Steering Column Reach Motor Noise
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
SITUATION:
NOISE FROM MECHANISM DURING REACH ADJUSTMENT
NOTE:
Reach mechanism "jamming" will generally be the result of improper lubrication. Refer to TIB 57/04/05/NA5 for guidance on the lubrication
only procedure associated with reach mechanism jamming.
The customer may complain that during reach adjustment a noise is evident from the steering column during the adjustment motion.
RESOLUTION:
STEERING REACH MOTOR REPLACEMENT
Upon customer complain of the noise symptoms during reach adjustment, follow the Repair Procedure outlined in this bulletin to install a reach
motor kit. If it is determined during troubleshooting that the reach motor has electrical faults this procedure may also be followed.
PARTS INFORMATION:
NOTE:
There is no requirement to replace anything other that the motor to repair a reach mechanism adjustment noise condition or an reach motor
electrical fault. The steering column assembly is not required.
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
REPLACE REACH MOTOR
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LM Range
Rover/2005 > Workshop Manuals > Service
Procedures > Bookmark "STEERING/REPAIRS" >
link "Column assembly - inner & outer"
1. Refer to GTR Workshop Manual section 57.40.01 and remove the steering column assembly.
191
2. Release and remove the reach motor from the steering column. (Figure 1)
NOTE:
Broken plastic motor clips may be found upon disassembly or may occur during motor removal. Broken clips will be replaced later in the
procedure.
3. If the plastic motor clip is unbroken, leave it in position.
4. Remove the flexible drive from the steering column.
5. Refer to the steering column bar code label (Figure 2) and determine if the column number is before or after column number "73067" (Week
Number 44 Year 03)
6. If the column number is before "73067" perform the following:
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^ Insert the special tool, part number QME500100, into the square drive of the spindle. (Figure 3)
^ Hold the shaft with the tool and release the spindle nut half a turn. (Figure 4)
^ Hold the shaft with the tool and tighten the spindle nut to 6Nm (4.5 lbf.ft). (Figure 5)
193
^ Hold the shaft with the tool and release the spindle nut one "flat." (Figure 6)
^ Remove the tool.
7. If the plastic motor clip is broken, or breaks during motor removal, perform the following:
^ Remove the broken clip by levering it off. (Figure 7)
CAUTION:
It is critical that the plastic clip is fully engaged into the steering column aluminum body. There will be a loud snapping noise as the clip
engages.
^ Align the key on the new plastic motor retaining clip with the machined slot on the aluminum body of the column
^ Snap the new clip into position.
^ Verify that the key is located in the slot and the clip is securely located.
194
8. Insert the flexible drive into the spindle. (Figure 8)
9. Slide the new motor fully back into the plastic clip, guiding the flexible drive into the gearbox.
10. Verify that the peg locates fully into the motor and that the motor is correctly located in the clip. (Figure 9)
11. Apply a thin bead of grease onto the tilt and reach
12. Refer to GTR Workshop Manual section 57.40.01 and install the steering column assembly.
DisclaimerLand Rover Range Rover Technical Service Bulletin # TA004402 Date: 001122
Recall - A/T Breather Hose Repositioning
TA00 4402
195
November 22, 2000
ATTENTION:
General Manager
Sales Manager
Service Manager
Service Advisor
Technician
AT Breather Repositioning and Fluid Check
IMPORTANT NOTE:
This Technical Alert supersedes and replaced TA00 4401
NOTE: The Service Action described in this Technical Alert is required due to a safety defect notification made by Land Rover North America to
NHTSA. Ensure that this Technical Alert is routed immediately to all of the persons in the "ATTENTION" distribution.
Land Rover North America will be issuing a Safety Recall for vehicles in service that are within the affected VIN range. Appropriate notices will be
mailed to all owners once the recall procedures are developed and verified for in-service vehicles.
VEHICLES WITHIN THE AFFECTED VIN RANGE THAT ARE IN RETAILER STOCK MUST BE MODIFIED PRIOR TO SALE.
This Service Action is to be executed on all affected new and used vehicles in Retailer inventory prior to delivery.
The Repair 1 procedural steps only apply to undelivered vehicles which have not been deep water waded, which do not have a warranty start date
activated and have less than 500 miles on the odometer.
The Repair 2 procedural steps apply to new and used vehicles in retailer inventory which have in excess of 500 miles on the odometer.
NOTE:
Used vehicles within the VIN range in retailer inventory, INCLUDING DEMOS WITH AN ACTIVE WARRANTY DATE, must pass the AT
fluid test outlined below. Vehicles that fail the visibility test may not be retailed until the Recall bulletin for vehicles with accumulated mileage
has been issued.
No action is to be taken on vehicles that have been delivered to customers. Delivered vehicles will be addressed by the Recall bulletin where
additional procedures will be outlined.
AFFECTED VEHICLE RANGE:
Range Rover (LP) XA410504 to 1A449412
Discovery Series II (LT) XA200000 to 1A299999
XA900000 to XA907212
1A700000 to 1A706116
SITUATION:
TRANSMISSION WATER INGRESS THROUGH BREATHER
Condensation from Air Conditioning and water from a "deep wading" event can flow over the transmission and collect on the transmission breather
tube on Range Rover and Discovery Series II vehicles. It can then migrate up the transmission tube. Over time these small water droplets can cause
an accumulation of water in the transmission causing problems associated with water contamination - harsh gear changes, poor gear selection, gear
slip or loss of drive and intermittent failure of the park lock function. Inspections and resolution for these faults will be addressed by the formal
Recall.
RESOLUTION:
REPAIR 1: REPOSITION BREATHER TUBE AT PDI - NEW VEHICLES UP TO 500 MILES
At or before delivery of a vehicle to a purchaser, re-route the breather tube to the top of the transmission to eliminate the breather tube as a source of
transmission contamination.
REPAIR 2: REPOSITION BREATHER TUBE AND INSPECT FLUID - NEW AND USED VEHICLES OVER 500 MILES
At or before delivery of a vehicle to a purchaser test the AT fluid as outlined in the Procedure section of the Alert. If the AT fluid is found to be
uncontaminated by the test, re-route the breather tube to the top of the transmission to eliminate the breather tube as a source of transmission
contamination.
196
PARTS INFORMATION:
WARRANTY CLAIMS:
REPAIR PROCEDURE
CAUTION:
No vehicle that has been waded, or has been delivered to a customer is to be corrected following the breather hose positioning procedure ONLY.
Additional instructions for in-service vehicles will be provided at a later time in a Recall bulletin.
REPAIR 1: POSITION BREATHER TUBE - VEHICLES UNDER 500 MILES IN RETAILER INVENTORY
1. Raise vehicle on lift.
2. Locate end of transmission breather tube clipped to the edge of the transmission pan. (Figure 1)
3. Inspect the end of the tube for blockage or damage.
4. Unfasten clip from transmission and remove the clip from the tube. Discard the clip.
5. Guide the end of the breather tube up over the top of the transmission housing.
6. Locate the white three-hole tube-locating clip near the top of the transmission housing.
7. Spray a small amount of silicon lubricant on the breather tubing near the locating clip.
CAUTION:
The orientation of the breather pipes is slightly different on Range Rover and Discovery Series II vehicles
^ On Discovery the Transfer Gearbox breather and the Gearbox breather come from opposite sides of the vehicle.
^ The Discovery breather is secured to an electric harness and must be released from that restraint.
^ Movement of the white clip is limited by the divergence of the tubes.
^ Care must be exercised to avoid crimping or deforming the tubing.
197
8. On Range Rover vehicles slide the white tube clip toward the rear of the vehicle until it stops against the bulge at the end of the repositioned
drain tube. (Figure 2)
9. On Discovery Series II vehicles perform the following:
^ Snip the cable tie to release the breather tube from the electrical harness.
^ Slide the white tube clip toward the rear of the vehicle until resistance is met because of the divergence of the transmission and transfer
box tubes. (Figure 3)
^ Verify that the end of the breather tube is parallel with the AT breather and pointed toward the LH rear of the vehicle.
10. Wipe any residual silicon lubricant from tubes.
REPAIR 2: POSITION BREATHER TUBE AND INSPECT AT FLUID FOR CLARITY VEHICLES IN RETAILER INVENTORY OVER 500
MILES
1. Raise the vehicle on a lift.
NOTE:
The testing process outlined below must be followed carefully to avoid unnecessary loss of AT fluid. Done with care and with the proper
tools, approximately 100 cc (3-4 oz.) of fluid can be drained for evaluation. You must have approximately two inches of fluid in the bottom
of your container when the fluid sample is taken.
CAUTION - Fluid drained from the sump pan may be "hot" - Due care and attention must be observed when draining the fluid.
2. Test the fluid to determine the presence of water contamination as follows:
^ Obtain a clean clear plastic container about three inches in diameter and about 6 inches tall.
^ Using a 5 mm Allen wrench break the seal on the transmission drain plug.
^ Orient the Allen wrench with the long portion vertical and carefully unscrew the plug until AT fluid seepage is observed.
^ Hold the container under the plug opening and carefully unscrew the plug until no threads are engaged but maintaining pressure against the
opening.
198
^ Tilt the plug slightly to drain the fluid sample required to give 1.5 to 2 inches of fluid in the bottom of the container.
^ Thread the plug back into the opening.
NOTE:
If a level of uncertainty exists as to the correct appearance of the sample, a comparison of the sample taken to new fluid from stock will be
helpful.
3. Visually inspect the fluid for the presence of water contamination against the following parameters:
^ Uncontaminated fluid will have a bright red appearance and will be "clear." You can easily see your finger on the bottom of the clear
container from the top through the 2 inches of drawn fluid.
^ Lightly contaminated fluid will have a deep burgundy red color and cloudy appearance,
^ Heavily contaminated fluid will have a "milky pink" appearance.
WARNING:
Contaminated transmissions may experience intermittent failure of the park lock function. Recall inspection and repair process will be
issued for vehicles that exhibit symptoms of contaminated fluid.
4. If the gearbox fluid exhibits a contaminated appearance THE VEHICLE MUST NOT BE SOLD and no further action can be taken until the
issuance of the formal Recall documentation and procedures.
5. If the gearbox fluid is clear perform the following:
^ Re-route the gearbox breather pipe as described in procedure "Position Breather Tube - Vehicles under 500 miles in Retailer Inventory"
^ Top up the transmission fluid level to the correct level making sure to follow the procedure outlined in TIB 441011981NA5.
^ Install the campaign label as outlined in the next section.
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:
199
^ Campaign code performed ("5E25")
^ Your Retailer code
^ The date of repair
2. Peel the label back, apply to radiator support and roll the label with the special roller.
Land Rover Range Rover Technical Service Bulletin # TEC510100 Date: 000407
Differential - Rear Axle Vent Leaks
No: 51/01/00/NAS
Ref:
Issue: 1
Date: 04/07/00
Rear Axle Oil Leak
AFFECTED VEHICLE RANGE:
Range Rover (LP) XA410483 to YA431506
SITUATION:
TRAPPED BREATHER CAUSES OIL LEAK
On vehicles in the above VIN range the customer may observe a rear axle oil leak, The leak may be the result of the axle breather pipe becoming
trapped by the right hand rear air spring. This can cause pressure build up in rear axle as the result of the damaged pipe.
RESOLUTION:
RELOCATE BREATHER TUBE
Confirm the origins of the leak. Install a new breather to replace a damaged piece and secure the breather tube as described in this bulletin.
PARTS INFORMATION:
FTC5133 Breather Pipe Qty 1
NTC1154 Cable Tie Qty 1
NRC9246 Pipe Clip Qty 1
WARRANTY CLAIMS:
NOTE:
Time allowance does not include any additional oil leak rectification.
51.27.89/26 Time 0.25 hrs.
Install new breather pipe
FAULT CODE: M
Normal warranty policy and procedures apply
REPAIR PROCEDURE
1. Confirm the source of oil leakage.
2. Inspect breather pipe FTC5133 for damage and replace if necessary.
200
3. Referring to Figure 1 and pass cable tie NTC1154 through the tie slot in pipe clip NRC9246.
4. Pass the tie wrap around axle tube.
5. Secure cable tie approximately mid way between axle tube breather entry "A" and the air spring mounting plate "B" as shown in Figure 1.
6. Secure the breather hose into the new clip.
7. Ensure that the hose is routed clear of the air spring, particularly when suspension ride height "Access" mode is selected.
8. Verify rear axle lubricant level and top-up as required.
Land Rover Range Rover Technical Service Bulletin # TEC4102973 Date: 991123
Transfer Case - Output Seal Leakage
No: 41/02/97/NAS
Ref: WSM section 41
*Issue: 3
Date: 11/23/99*
PRIDE IV 4-08
Transfer Gearbox Output Seal Replacement
AFFECTED VEHICLE RANGE:
*RANGE ROVER (LP) All*
* indicates updated information
SITUATION:
TRANSFER GEARBOX OUTPUT SEALS LEAKING
Transfer gearbox output seals may be found to be leaking. If either the front or the rear output shaft seal is leaking, both should be replaced.
RESOLUTION:
REPLACE TRANSFER GEARBOX OUTPUT SEALS
*Redesigned output shaft oil seal kits are now available for the Borg Warner Electronic Shift Transfer Gearbox used on Range Rover. The new seals
in the kits utilize an improved material and a twin lip seal design which incorporates an additional dust lip to ensure long seal life. The new seals are
installed to a greater depth than the original seals. New Flanges must also be installed in conjunction these seals.*
CAUTION:
Use new tool LRT-41-013 to install the seals. (Do not use LRT-41-011)
201
PARTS INFORMATION:
*NOTE:
All of the parts necessary for this repair are now available in two kits. One is for the rear seal, and the other is for the front. The following part
numbers are kits that include all parts referenced in issue two of this bulletin.*
*STC4380 Seal and Flange Kit Front*
^ STC3897 Flange Assembly - Front Output
^* 571970 Mudshield - Transfer box Oil Seal - Rear*
^ FTC4939 Seal - transfer box output
^ RTC6363 Seal - transfer box output flange spline
^ NY112041L Nut- nyloc - M12
*STC4381 Seal and Flange Kit Rear*
^* STC3244 Flange Assembly - Rear Output*
^ FTC4939 Seal - transfer box output
^ RTC6363 Seal - transfer box output flange spline
^ NY112041L Nut - nyloc - M12
WARRANTY CLAIMS:
41.20.51 Time 1.05 hrs.
Replace Front Output Shaft Seal
41.20.54 Time 0.85 hrs.
Replace Rear Output Shaft Seal
FAULT CODE: N
Normal warranty policy and procedures apply
REPAIR PROCEDURE:
REAR SEAL REPLACEMENT
1. Following instructions found in WSM section 41 remove rear drive shaft, parking brake drum, oil seal, and flange assembly.
CAUTION:
Use care in order to avoid damaging the seal installation area of the transfer gearbox.
2. Lubricate new seal lip with transmission fluid and install seal using tool LRT-41-013.
3. Carefully clean any oil found on the parking brake backing plate, shoes and drum.
CAUTION:
A new style flange must be installed on the front output shaft when replacing the seal.
4.* Install new output flange.
5. Replace rubber-sealing washer with transfer box output flange spline seal RTC6363.
6. Fit washer and Nyloc nut finger tight.*
7. Install parking brake drum and secure to flange with screw.
202
8. Adjust parking brake shoes and apply parking brake.
9. Tighten Nyloc nut to 220 Nm. (162 lbf.ft).
10. Reinstall remaining components as described in WSM section 41.
FRONT SEAL REPLACEMENT
1. Following instructions found in WSM section 41 remove front drive shaft, oil seal and flange assembly.
CAUTION:
Use care in order to avoid damaging the seal installation area of the transfer gearbox.
2. Lubricate seal lip with transmission fluid and install seal using tool LRT-41-013.
CAUTION:
A new style flange must be installed on the front output shaft when replacing the seal.
3.* Install new mudshield and flange.
4. Replace rubber-sealing washer with transfer box output flange spline seal RTC6363.
5. Fit washer and Nyloc nut finger tight.*
6. Tighten nut to 220 Nm. (162 lbf.ft).
7. Reinstall remaining components as described in WSM section 41.
8. Top off transfer gearbox with Dexron III ATF.
Land Rover Range Rover Technical Service Bulletin # TEC760300 Date: 000915
Body - Lower Tailgate Won't Release
No: 76/03/00/NAS
Ref:
Issue: 1
Date: 09/15/00
Tailgate Release Adjustment
AFFECTED VEHICLE RANGE:
Range Rover (LP) WA410382 to YA437175
SITUATION:
LOWER TAILGATE DOES NOT RELEASE
A customer may complain that the lower tailgate latch does not release when the release button is pressed. This condition is likely the result of
incorrect center latch alignment.
RESOLUTION:
203
ADJUST TAILGATE LATCH
Incorrect setting of the tailgate center latch can be corrected to ensure simultaneous release of both lower tailgate latches by following the procedure
outlined below. Correct alignment and proper tightening of the center latch are both critical to proper tailgate release.
PARTS INFORMATION:
No parts involved
WARRANTY CLAIMS:
76.37.17 Time 0.25 hrs.
Adjust tailgate latch assembly
FAULT CODE: Z
Normal warranty policy and procedures apply
REPAIR PROCEDURE
1. Refer to the WSM repair operation 76.37.17 and remove lower tailgate carpet.
2. Loosen the two center latch retaining bolts (Figure 1).
3. Tighten bolts just enough to allow the latch to hold its position but still move.
4. Close the lower tailgate to align the latch.
5. Taking care not to disturb the position of the latch, tighten the two retaining bolts to a torque of 9 Nm (80 lbf.in.).
6. Verify simultaneous operation of both latches
7. Confirm that tailgate release operation is now satisfactory.
8. Install the tailgate carpet.
Land Rover Range Rover Technical Service Bulletin # TEC761305 Date: 050707
Body - Difficult to Latch Lower Tailgate
No: 76/13/05/NAS
FGN LM501-03
Ref:
Issue: 1
Date: 07 July 2005
Difficulty Latching Lower Tailgate
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
204
SITUATION:
DIFFICULTY LATCHING LOWER TAILGATE
A customer may complain that it is difficult to latch the lower tailgate on one or both sides of the vehicle. The failure of the lower tailgate to latch to
operate properly may be due to slight distortion of the latch mechanism caused by minor unevenness of the mounting surface. The complaint may not
be evident immediately and may appear after some period of use.
RESOLUTION:
INSPECT FOR LATCH RESISTANCE AND SPACE LATCH AWAY FROM BODY
Should a customer complain about difficulty latching the lower tailgate, the manual latch release lever should be operated on both sides of the lower
tailgate to check for noticeable resistance. When resistance is confirmed insert washers under each latch to prevent latch distortion from an uneven
mounting surface.
NOTE:
Latch distortion, and resistance during operation can be repaired using the process in this bulletin. The latch should not be replaced to address
this concern.
PARTS INFORMATION:
WA108051L Washer, 8 mm Qty 4 Ordered in quantity pack of 50
DDW WARRANTY CLAIMS:
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.
NOTE:
Land Rover part number WA108051L is a package containing 50 washers. This service procedure requires only 4 washers. Only a 12.5 %
proportion of the Retail value of the package WA108051L may be claimed against Warranty Claim Code ZZZ001. Any claims for a greater
portion of the value will be subject to warranty audit. will be subject to warranty audit.
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
VERIFY LATCH OPERATION AND INSTALL WASHERS
1. Shut the lower tailgate and determine whether the LH or RH latch assembly is failing to latch.
2. Open the lower tailgate.
NOTE:
Manual operation of the release lever will indicate resistance during the unlatching motion. The sticking of the mechanism is a result of slight
distortion of the latch internal components. There is no need to replace the latch to resolve this complaint.
205
3. Operate the manual release lever of the suspect latch to verify increased resistance. (Figure 1)
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LM New Range Rover/2005 > Workshop Manuals > Service Procedures > Bookmark "76-1 Doors"
> Link "76.37.83 Latch outer-tail gate"
4. Refer to GTR Workshop Manual section 76.37.83 and remove the latch from the lower tailgate. (Figure 2)
206
5. Place a washer (WA108051L) on each of the latch retaining bolts. (Figure 3)
6. Refer to GTR Workshop Manual section 76.37.83 and install the latch to the lower tailgate with the washers between the latch and the tailgate
surface. (Figure 4)NOTE: The washer installation will prevent any mounting surface irregularity from distorting the latch internals by creating
a slight gap between latch and lower tailgate surface. (Figure 4)
7. Close lower tailgate and confirm correct latch operation.
8. Perform steps 4 through to 7 for the alternate side lower tailgate latch to ensure correct operation of both latches.
Disclaimer
Land Rover Range Rover Technical Service Bulletin # TEC570105 Date: 050307
Steering - Squeaking Noise From Bulkhead When Turning
207
No: 57/01/05/NAS
FGN LM211
Ref: 57/02/03/NAS
Issue: 1
Date: March 07, 2005
Power Steering Squeak at Bulkhead
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
SITUATION:
STEERING NOISE WHEN TURNING
A customer may report a concern of a squeaking noise from the bulkhead area when turning the steering wheel. The noise level does not change with
road speed but may vary, depending on speed of steering wheel rotation, and temperature.
RESOLUTION:
FLUSH AND CYCLE THE POWER ASSISTED STEERING SYSTEM
NOTE:
A similar squeak can be traced to the steering column bushing and grommet. Refer to TIB 57/02/03/NAS for additional information on the
lubrication of the grommet to eliminate this noise source.
If a customer expresses concern about the squeaking noise, refer to the Service Procedure detailed in this bulletin. The likely cause is steering rack
pinion seal squeaking against the pinion.
PARTS INFORMATION
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
REPAIR PROCEDURE
NOTE:
This procedure requires the power assisted steering (PAS) system to be cycled through full left steering lock to full right steering lock
without the engine running and without the front wheels freely suspended.
1. With the vehicle on a suitable lift, locate the front wheels onto swivel plates to enable the steering to be cycled lock to lock without the engine
running.
2. Open the hood.
3. Clean the area around the PAS fluid reservoir cap and remove the reservoir cap.
NOTE:
GTR lookup sequence is as follows: GTR Home > NAS > Service Information/LM Range Rover/2004 > Workshop Manuals > Service
Procedures > "EXTERIOR FITTINGS/REPAIRS > "Undertray - front" link.
4. Refer to GTR Section 76.11.81 and remove the engine undertray.
208
5. Position a suitable container to collect PAS fluid spillage under the vehicle.
CAUTION:
Before disconnecting PAS joints, ensure the immediate area around the joint is clean to prevent contamination.
6. Disconnect the PAS supply hose as follows:
^ Note the orientation of the PAS fluid supply hose to Figure the PAS pump. (Figure 1)
^ Loosen the union nut.
^ Disconnect the hose.
^ If undamaged, retain the 0-ring seal for refill-flush-drain procedure.
^ Allow the PAS fluid to drain from the system.
CAUTION:
The front wheels must not be freely suspended during the purge process.
7. With the vehicle placed on the swivel plates and Supply without engine running, cycle the steering ten times through full left steering lock to
full right steering lock to ensure maximum quantity of fluid is purged from the system.
NOTE:
Ensure a new 0-ring seal is installed to the PAS pump hose prior to final assembly.
8. Clean the residual fluid from the PAS pump and reconnect the supply hose in its original orientation with washer.
9. Fill the PAS reservoir with new PAS fluid (LRN2261).
10. Start the engine and allow to idle for two minutes while slowly cycling the steering lock to lock.
NOTE:
GTR lookup sequence is as follows: GTR Home > NAS > Service Information/LM Range Rover/2004 > Workshop Manuals > Service
Procedures > "STEERING/ADJUSTMENTS" > "Power assisted steering (PAS) system - bleed" link.
11. Refer to GTR section 57.12.02 and add PAS fluid to the PAS reservoir when necessary as air is purged from the system.
12. Switch engine off.
13. Repeat drain procedure from step 6, before proceeding to step 14.
14. Refer to GTR section 76.11.81 and install engine undertray.
15. Ensure PAS reservoir fluid is at the correct level and install reservoir cap.
16. Remove vehicle from lift and swivel plates.
CAUTION:
Do not hold the steering at full steering lock for longer than one second, as this may overheat the PAS fluid.
17. Start engine and position the vehicle in a suitable location to perform the following static steering maneuver:
^ Quickly turn the steering to full right steering lock and 'bounce' steering on/off full lock five times.
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^ Quickly turn the steering to full left steering lock and 'bounce' steering on/off full lock five times.
^ Complete five repetitions of the following steering cycle - full lock, to hold, to 90 degrees back.
^ Turn the steering to full right steering lock
^ Hold for one second
^ Quickly turn steering back 90 degrees.
^ Complete five repetitions of the following steering cycle - full lock, to hold, to 90 degrees back.
^ Turn the steering to full left steering lock
^ Hold for one second
^ Quickly turn steering back 90 degrees.
18. Re-test vehicle for the squeaking noise.
19. If the fault is still apparent, repeat the steering maneuver in step 17.
20. Verify that the PAS reservoir fluid is at the correct level following bleed and test process.
Land Rover Range Rover Technical Service Bulletin # TEC820105 Date: 050316
A/C - Vibrating Noise at Highway Speeds
No: 82/01/05/NAS
FGN LM412
Ref:
Issue: 1
Date: March 16, 2005
AFFECTED VEHICLE RANGE:
Range Rover (LM) Up to 5A181087
SITUATION:
NOISE AT HIGHWAY SPEEDS FROM HVAC SYSTEM
A customer may report a concern of a noise from behind the instrument panel when the Heating Ventilation Air Conditioning (HVAC) is in
Recirculation or Automatic mode. The noise is evident at road speeds of above 60 mph (100km/h). The HVAC recirculation flap seals may be
vibrating against the heater body as incoming air passes over them.
RESOLUTION:
INSTALL FLAP SERVICE KIT
Should a customer express concern regarding a heater noise as described, follow the repair procedure in this bulletin to replace the HVAC seals.
PARTS INFORMATION
DDW WARRANTY CLAIMS:
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DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
REPAIR PROCEDURE
INSTALL HVAC FLAP SERVICE KIT
NOTE:
GTR lookup sequence is as follows: GTR Home > NAS > Service Information/Lm Freelander/2004 > Workshop Manuals > Service
Procedures > Bookmark "INTERIOR FITTINGS/REPAIRS" > "Fascia - carrier" link.
1. Refer to GTR section 76.46.22 and remove the instrument panel and carrier.
2. Select one side of the heater assembly to work on.
3. Release the securing clips and remove the selected side recirculation flap motor. (Figure 1)
NOTE:
The right-hand Bowden cable is blue and the left hand cable is green.
4. Remove the Bowden cable from the securing clip on the recirculation flap housing. (Figure 2)
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5. Using long-nosed pliers perform the following: (Figure 3)
^ (1) Gently squeeze the central tags of the flap operating cam together.
^ (2) Release the cable from the flap operating cam.
6. Using long-nosed pliers perform the following: (Figure 4)
^ (1) Gently release the tags inside the operating cam center.
^ (2) Remove the recirculation flap operating cam from the recirculation flap-arm.
7. Rotate the flap forward to gain access to the recirculation flap-spindle, lower mounting. (Figure 5)
CAUTION:
Care must be exercised to avoid damaging the components behind the recirculation flap, or the flap spindle-mounting.
8. Using a lever, gently ease the recirculation flap spindle out of the lower mounting.
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9. Rotate the flap to the open position and release the flap-spindle from the top mounting. (Figure 6)
10. Remove the flap from the HVAC housing.
NOTE:
The new recirculation flap is identified by an "L" for the left-hand side flap and "R" for the right-hand side flap.
11. Install the new flap assembly into the HVAC housing as follows:
^ Insert the top flap-spindle into the top mounting.
^ Ease the lower flap-spindle into the lower spindle mounting.
NOTE:
The new operating cam supplied in the service repair kit, is designed to locate onto the recirculation flap-arm in one position only.
12. Install the new operating cam.
NOTE:
The right-hand Bowden cable is blue and the left hand cable is green.
13. Install the operating rod and Bowden cable.
14. Install the recirculation flap motor.
15. Repeat steps 2 - 14 for the alternate side recirculation flap.
16. Refer to GTR Workshop Manual Section 76.45.22 and install the instrument panel and carrier.
Land Rover Range Rover Technical Service Bulletin # G97-018 Date: 970822
Towing - Flat Towing Behind a Motorhome
Bulletin: G97-018
Section: GENERAL
Date: 8-22-97
Model:
Applicable to: USA/Cda
Subject:
Flat Towing Guidelines
There is a bit of confusion amongst our associates and customers regarding the proper procedures for flat towing (four wheels on the ground) Land
Rover vehicles i.e. behind a motorhome. Below, please find the approved procedures for each of our models:
Range Rover 4.OSE & 4.6HSE
^ Engage handbrake
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^ Automatic transmission gear selector lever in "park"
^ Select transfer box neutral
1. Remove ignition key
2. Insert a fuse (5 amps or greater) in fuse position "11" in the right hand seat fuse box
3. Insert ignition key, turn to position "2" (transfer box will automatically select neutral)
4. After message centre displays 'TRANSFER NEUTRAL', turn ignition switch to "0" position
^ From "0" position, turn ignition switch to position "1', (switching the ignition key from position "0" to position "1" allows the steering column to
remain unlocked with no electrical accessories engaged to discharge the battery). ^Note: The BECM (Body Electronic Control Module) will not
"sleep" with ignition key in switch. It is suggested on prolonged towing, that the vehicle be started and run for a minimum of 15 minutes every
other day.
^ Release the handbrake only after the vehicle is properly attached to the tow vehicle
^ Refer to owners handbook, Emergency Towing section, for transfer box re-engagement procedure
Range Rover Classic, Discovery Auto, Defender Auto:
^ Engage handbrake
^ Select transfer box neutral
^ Confirm neutral has been selected by safely rolling the vehicle with automatic transmission in park position (do not rely on the neutral warning
tone alone)
^ Ensure that
1. The centre differential is unlocked.
2. The automatic transmission gear selector lever is in "park", and
3. The ignition switch is in the number "1" position (switching the ignition key from position "0" to position "1" allows the steering column to
remain unlocked with no electrical accessories engaged to discharge the battery).
^ Release the handbrake only after the vehicle is properly attached to the tow vehicle.
Discovery 5spd and Defender 5spd
^ Engage handbrake
^ Select transfer box neutral
^ Confirm neutral has been selected by safely rolling the vehicle
^ Ensure that
1. The centre differential is unlocked.
2. The transmission is in neutral, and
3. The ignition switch is in the number "1" position (switching the ignition key from position "O" to position "1" allows the steering column to
remain unlocked with no accessories engaged to discharge the battery).
^ Release the handbrake only after the vehicle is properly attached to the tow vehicle.
When using a towing dolly with the rear wheels on the ground; the rear drive shaft must be disconnected from the rear axle and secured after the
vehicle is safely secured to the towing dolly.
AT ALL TIMES PLEASE OBSERVE GOOD SAFETY PRACTICES
Land Rover Range Rover Technical Service Bulletin # TEC540105 Date: 050318
Drivetrain - 'Select Neutral' Message Displayed
No: 54/01/05/NAS
214
FGN LM205
Ref:
Issue: 1
Date: March 18, 2005
Unexplained "SELECT NEUTRAL" Message Display on Instrument Pack
AFFECTED VEHICLE RANGE:
Range Rover (LM) All
SITUATION:
"SELECT NEUTRAL" MESSAGE DISPLAYED
A customer may report a concern that the 'Select Neutral' message is illuminated on the Instrument Panel message center. A second message for 'Low
Range' may also illuminate. Engine speed may not maintain expected vehicle road speed.
RESOLUTION:
INSPECT FOR DRIVESHAFT DISENGAGEMENT
Upon customer complaint of the "Select Neutral" message refer to the Repair Procedure detailed in this bulletin. Diagnosis may reveal that the root
cause of the display and symptoms is the disengagement of a front driveshaft from the differential.
PARTS INFORMATION
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
REPAIR PROCEDURE
INSPECT DRIVESHAFT ENGAGEMENT
1. Carry out the following steps to verify if disengagement of a driveshaft is the cause of the complaint:
^ Raise the vehicle so the front wheels are freely suspended.
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^ Verify that there is no visible gap between the front driveshaft inboard joint and the differential housing on the left-hand side. (Insert
"check mark" in Figure 1)
^ Verify that there is no visible gap between the front inboard joint and the engine sump on the right-hand side. (Insert "Check mark" in
Figure 1)
CAUTION:
If the driveshaft retaining circlip is disengaged, manual force alone will be sufficient to move the driveshaft inboard joint from its correct
location (Dashed arrow in Figure 1). Tools or levers should NOT be used as this may cause the disengagement of the circlip.
NOTE:
Marginal driveshaft retaining circlip engagement, can cause an intermittent condition. Therefore it is important that circlip engagement be
checked carefully.
^ Inspect both of the front drive shafts and verify they are fully engaged into the differential.
^ Manually check the security of the drive shaft inboard joint into the differential housing.
REPAIR OR REPLACE DRIVESHAFT
NOTE:
GTR lookup sequence is as follows: GTR Home > North America > Service Information/LM New Range Rover/2005 > Workshop
Manuals > Service Procedures > Bookmark "DRIVESHAFTS/REPAIRS" > link "Drive shaft - front - LH or RH"
1. If driveshaft disengagement is identified as the root cause, refer to GTR Workshop Manual Section 46.10.01 or 47.10.02 and remove the
affected driveshaft.
2. Inspect the driveshaft for damage that could affect retention of the new circlip.
3. If the driveshaft is not damaged, perform the following:
^ Install a new retaining circlip and re-install the original driveshaft.
^ Manually check the security of the drive shaft inboard joint into the differential housing.
^ Claim driveshaft remove and replace as a separate warranty repair.
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4. If the driveshaft is damaged, perform the following:
^ Install a new driveshaft and circlip.
^ Manually check the security of the drive shaft inboard joint into the differential housing.
^ Claim driveshaft remove and replace as a separate warranty repair.
Land Rover Range Rover Technical Service Bulletin # TEC470105 Date: 050623
Drivetrain - Vibration During Low Speed Maneuvers
No: 47/01/05/NAS
FGN LM205-04
Replaces: 47/01/03/NAS
47/01 104/NAS
Issue: 1
Date: 23 June 2005
Steering Vibration During Low Speed Maneuvers
AFFECTED VEHICLE RANGE:
New Range Rover (LM) Up to 5A195343
SITUATION:
STEERING WHEEL / VEHICLE VIBRATION
When the steering wheel is turned sharply to the left-hand or right-hand the customer may complain of a vibrating sensation through the steering
system or in the body of the vehicle. The vibration may be evident in the vehicle cabin under the following conditions:
^ When turning the steering wheel towards either lock, with the foot brake applied and drive selected
^ Slow speed parking maneuvers
The right-hand or left-hand front driveshaft extends in length when steering towards right-hand or left- hand lock respectively. During this extension,
the ball bearing cage located within the driveshaft assembly can contact the circlip if the ball bearing cage is out of position.
RESOLUTION:
REPLACE DRIVESHAFTS
NOTE:
This procedure replaces the processes outlined in previously published bulletins 471011031NAS and 47/01/04/NAS.
Should a customer express complain of the above vibration symptoms, follow the rectification procedure below to replace the original drive shafts
with the latest configuration components.
PARTS INFORMATION:
DDW WARRANTY CLAIMS:
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.
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
217
Normal warranty policy and procedures apply.
REPAIR PROCEDURE REPLACE DRIVESHAFTS
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LM New Range Rover/2005 > Workshop Manuals > Range Rover Workshop Manual - Service
Procedures > Bookmark "DRIVESHAFTS/REPAIRS" > Driveshaft front LH" or "Driveshaft front RH" link
1. Refer to Range Rover (LM) Workshop Manual Sections 47.10.01 and 47.10.02 and replace both LH and RH front drive shafts.Technical
Service Bulletin # TEC860704 Date: 041028
Electrical - Warning Lamps/Various System Malfunctions
No: 86/07/04/NAS
Ref:
Issue: 1
Date: 28 October 2004
False BCU Input Signal
AFFECTED VEHICLE RANGE:
Range Rover (LM) up to 4A162652
SITUATION:
FALSE BCU INPUT SIGNAL
A false input signal to the Body Control Unit (BCU) can result in a series of symptoms (hazard lamps flashing, doors unlock, radio goes mute and
the interior lights illuminate). An electrical spike within the internal electrical circuits may be the cause of the problem.
RESOLUTION:
REPLACE AND CONFIGURE THE BCU
Should a customer complain of these symptoms, replace the BCU and configure the new unit using T4.
PARTS INFORMATION:
YWC000922......BCU Qty 1
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
1. Connect T4 to the vehicle and load disc Range Rover 14 or a later version.
2. Begin a new T4 diagnostic session and perform the following observing all on-screen instructions:
^ Select "System Diagnostics"
^ Select "Security"
^ Select "Vehicle Maintenance"
^ Select "ECU Renewal"
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Select "Body Controller"
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information / LM New Range Rover/2004 > Workshop Manuals > RR WSM Service Procedures > Bookmark
"CONTROL UNITS AND RELAYS/REPAIRS/Body Control Unit (BCU)" > Section 86.55.75
^ Refer to GTR section 86.55.75 and when prompted by 14 follow the procedures to replace the Body Control Unit.
^ Configure the new BCU with T4.
3. After the BCU has been configured, program the remote handsets.
4. End the diagnostic session and return to the "Welcome" screen.
5. Disconnect T4 from the vehicle.Land Rover Range Rover Technical Service Bulletin # TECLM2110022 Date: 060420
Steering - Incorrect Steering Wheel Alignment
No: LM-211-002
Issue: 2
Date: 20 Apr 2006
CHANGES MADE FOR ISSUE "2" ARE SHOWN BY ASTERISKS
SECTION: 211-00
Steering Wheel Alignment
AFFECTED VEHICLE RANGE:
Range Rover (LM)
VIN: ALL
CONDITION SUMMARY:
STEERING WHEEL ALIGNMENT DIAGNOSIS
This bulletin is to provide diagnostic clarification for steering wheel alignment during the initial vehicle preparation inspection road test.
Situation:
Steering wheel alignment is set during build and has a tolerance of +/- 3° as nominal. Road surfaces with excessive camber variation, or road wheel
curb strikes/other accidental damage can lead to mis-diagnosis of steering wheel misalignment.
Action:
The process detailed below provides information to prevent unnecessary adjustments of the steering wheel alignment.
PARTS:
No parts required. Information purposes only.
WARRANTY:
NOTE:
The information in this bulletin is provided for diagnosis, evaluation and EPQR reporting of steering wheel alignment during initial vehicle
preparation activities.
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
EVALUATION OF STEERING WHEEL ALIGNMENT
*NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LM - New Range Rover / 2006 > Range Rover 2006 - Workshop Manual - New Systems >
Bookmark "Chassis/Suspension/204-00: Suspension System - General Information" Link "Four-Wheel Alignment (57.65.04)"
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1. Refer to GTR section 204-05: Vehicle Dynamic Suspension, Ride Height Adjustments (60.90.03) and ensure vehicle ride height is set to
nominal specifications.
2. Refer to GTR section 204-00 - Four-Wheel Alignment (57.65.04) and ensure vehicle geometry is set to specification.*
NOTE:
Extreme care must be taken to ensure the influence of road camber does not adversely influence the perceived steering wheel alignment. If
feasible, check in both directions of the road used during the assessment.
3. Assess the steering wheel alignment for level spokes, when steering straight ahead on a level surface.
4. If the alignment error is less than +/-3° no further action is required.
ADJUSTMENT OF STEERING WHEEL ALIGNMENT
WARNING:
The safety precautions detailed in the Workshop Manual relating to supplementary restraint systems (SRS) must be adhered to.
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/LM - Range Rover/2006 > Range Rover - Workshop Manual - Legacy Systems > Bookmark "75 -
Restraint Systems" > Link "76.74.01 Airbag module - steering wheel"
1. If the error is greater than +/-3° refer to GTR Section 76.74.01 and remove the air bag assembly.
2. Inspect the steering wheel alignment marks. (Figure 1)
NOTE:
Where possible, photograph the alignment mark error for submission with the EPQR.
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/LM - Range Rover/2006
> Range Rover - Workshop Manual - Legacy Systems> Bookmark "57 - Steering" > Link "57.61.01 Steering Wheel"
3. If the marks are not aligned perform the following:
^ Refer to GTR section 57.61.01 and remove the steering wheel.
* ^ Digitally photograph the alignment mark error.*
^ Realign the marks.
^ Install the steering wheel.
220
4. If the marks are correctly aligned perform the following:
^ Check the vehicle for evidence of damage that may have caused front wheel misalignment.
^ Refer to GTR section 57.65.04 and reset the steering geometry to achieve a steering wheel alignment within +/-3° on the road test.
5. Assess the steering wheel alignment for level spokes, when driving straight ahead on a level surface.
6. When the alignment is correct, raise an Electronic Product Quality Report (EPQR):
^ Provide photographic evidence of the alignment mark error if present.
^ Indicate the extent of the original steering wheel misalignment using the letter ID that corresponds most accurately to the misalignment.
(Figure 2)
^ Indicate the corrective action taken.
*7. Calibrate the steering angle sensor using T4.*
DisclaimerLand Rover Range Rover Technical Service Bulletin # TEC100105 Date: 050928
Maintenance - Fluid Specifications/Applications
No: 10/01/05/NAS
Ref: Replaces
10/01/03/NAS
Issue: 1
Date: 28 September 2005
Maintenance Fluid Specifications for
221
"Legacy" Land Rover Vehicles
AFFECTED VEHICLE RANGE:
All "LEGACY Vehicles" (LH, LD, LJ, LP, LT and LM thru 2005)
SITUATION:
SPECIFICATION FOR VEHICLE FLUIDS
Because of the unique nature and limited availability of some Land Rover fluids and lubricants, confusion regarding fluid specifications and
applications can exist. The current listing contains a number of brand names and several Land Rover-specific fluids with part numbers.
NOTE:
Land Rover has announced increased cooperation with Castrol. Castrol product names will be recommended as required fluids and lubricants on
Land Rover vehicles where applicable.
RESOLUTION:
USE CORRECT FLUIDS FOR ALL SYSTEMS
The table of applications and the part number listings are provided to ensure use of the correct fluid specification.
PARTS INFORMATION:
WARRANTY CLAIMS:
Normal warranty policy and procedures apply.
NOTE:
A coolant specification change has been made for Range Rover vehicles. The 2005 specification "G48" fluid is to be used for every FLUID
CHANGE situation. The original Texaco AFC coolant fluid may be used and topped up until a coolant change is required. Mixing Texaco AFC
and BASF G48 for top-up purposes is permitted
CAUTION:
Mixing of the BASF G48 with Texaco XLC coolant used in LR3, Freelander, Discovery Series II and late Range Rover 4.0/4.6 can result in
premature erosion of the cylinder heads or other cooling system deterioration. Unapproved blending of coolants is to be avoided.
Warranty coverage could be affected by the use of unapproved coolants or the incorrect blending of fluids.
Failure to use specified fluids could lead to component failure. If component failures are found to be caused by use of improper fluids, warranty
charge-backs could be impose
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223
224
225
226
227
FLUID APPLICATIONS IN ALL VEHICLES:
Disclaimer
Land Rover Range Rover Technical Service Bulletin # TECLRA415001 Date: 060911
Audio System - Speaker Vibration/Rattle Noise Diagnosis
228
No: LRA415-001
Issue: 1
Date: 11 Sep 2006
SECTION: 415-03 - ENTERTAINMENT SYSTEM
Speaker Vibration or Rattle Noise Diagnosis
AFFECTED VEHICLE RANGE:
Land Rover Vehicles
CONDITION SUMMARY:
SPEAKER VIBRATION OR RATTLING NOISE DIAGNOSIS
Situation:
A customer may report a concern of a vibration noise or rattling sound from a speaker area. Various solutions are available to resolve the cause of
the reported noise.
This bulletin has been issued to provide Retailers with information and steps to correctly diagnose and resolve the reported noise.
Action:
Should a customer report a concern, verify that the noise is coming from an area near a speaker and refer to the steps outlined in the Repair
Procedures detailed in this bulletin to correctly diagnose the issue before replacing a speaker assembly. The information contained in the Repair
Procedure section should reduce the number of speaker assemblies that are being returned with "no fault found."
PARTS:
Refer to Microcat for the parts that are specific to the vehicle with the problem.
WARRANTY:
NOTE:
When reporting repairs under warranty for speaker related noise issues, only report under "audio" if the speaker has been replaced. For other
conditions and repairs report the issue under the appropriate trim area.
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
1. Identify the area of the reported noise.
2. Check that the trim panels surrounding the speaker are correctly secured and not causing any vibration which is being attributed to the speaker.
3. Check for any customer belongings in door pockets that could be causing the issue.
4. Check the door casing mounted speaker cover/grills as follows:
^ Press and hold each grill in turn
^ Determine if the noise changes or stops.
^ If the noise does change or stops, check that the cover/grill is secured correctly to the door casing.
NOTE:
When submitting a claim for securing a speaker cover/grill, the claim should be logged as "trim" and not "audio".
5. Properly secure the cover/grill where necessary.
6. If the noise persists, remove the door casing and perform the following:
^ Check the speaker for any obvious physical damage such as dented cones, rips or tears in the speaker membrane.
^ If damage is discovered replace the speaker.
CAUTION:
Care must be taken to avoid over-tightening the speaker retaining screws.
7. Check that all the speaker retaining screws are secure. Properly secure as necessary.
229
NOTE:
When submitting a claim for repairing a raffle in the door, wiring harness or component, the claim should be logged as "trim" and not
"audio".
8. Check the surrounding door structure, wiring harnesses and components for rattles, and properly secure where necessary.
9. Install a new speaker temporarily and determine if the problem is resolved.
NOTE:
If the problem does not return in the step below when the original speaker is installed, the original speaker is not the root cause.
10. If the new replacement speaker resolves the problem, perform the following:
^ Reinstall the original speaker to determine if the problem returns.
^ If the problem does not return examine the trim or wiring harness routing for the likely cause.
^ If the problem returns with the original speaker, install the new speaker.
11. During final assembly perform the following:
^ Check that the speaker wiring or any harness parts are not vibrating against the speaker assembly.
^ Correctly route and secure all wiring as necessary.
^ Check that the speaker wiring is not trapped or impeding the speaker assembly. Check that the speaker wiring connections are fully
inserted and secure.
DisclaimerLand Rover Range Rover Technical Service Bulletin # TECLRA501001 Date: 060622
Body - Windshield Damage Diagnostic Aid
No.: LRA501-001
Issue: 1
Date: June 22, 2006
SECTION: 501-11
Windshield Damage Diagnostic Aid
AFFECTED VEHICLE RANGE:
All Land Rover Vehicles
CONDITION SUMMARY:
INTERPRETATION OF GLASS DAMAGE SYMPTOMS
Situation:
This information only bulletin has been issued to aid Retailers to determine whether windshield damage has been caused by an outside influence, or
a manufacturing concern.
Action:
Follow the steps outlined in the Repair Procedure to determine whether windshield damage has been the result of outside damage.
PARTS:
230
Information only
WARRANTY:
231
232
233
234
NOTE:
The pages shown offer illustrations of common windshield damage conditions and how to determine if the damage is result of outside influences
(not warrantable) or of manufacturing problems (warrantable)
Normal warranty policy and procedures apply.
DisclaimerLand Rover Range Rover Technical Service Bulletin # TECLM204006 Date: 060816
Suspension - Vehicle Lowers Overnight
No.: LM204-006
Issue: 1
Date: August 16, 2006
SECTION: 204-05 - SUSPENSION SYSTEM
Vehicle Lowers Overnight - Air-Spring Leak
AFFECTED VEHICLE RANGE:
Range Rover (LM) VIN: up to 4A160029
CONDITION SUMMARY:
FRONT AIR-SPRING LEAK CAUSES VEHICLE RIDE HEIGHT TO LOWER OVERNIGHT
A customer may report a concern that the vehicle ride height lowers overnight.
Situation:
No obvious system leaks may be found, however, vehicles in a higher mileage range of 30,000-60,000 miles may develop hairline cracks in the
rubber material of the front air-spring. The cracks are likely located at the point where the air-spring rolls over the plastic base.
235
Action:
Should a customer express concern regarding the above, refer to the Repair Procedure detailed in this bulletin to verify the cause and replace the
air-spring as necessary.
PARTS
WARRANTY
REPAIR PROCEDURE
REPLACE FRONT AIR-SPRING
NOTE:
An air leak in the rubber material may be verified using a suitable leak detection fluid.
1. Verify which front air-spring(s) has a leak and requires replacement.
NOTE:
The latest specification air-spring assembly is identified by the manufacturer markings printed on the air-spring air bag as shown in Figure
1.
236
2. Verify the correct specification air-spring assembly has been ordered from the markings as shown in Figure as follows:
^ Right-hand air springs must start with DC01.
^ Left-hand air springs must start with DB01.
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/LM - Range Rover/2004 > Workshop Manuals > Range Rover - Workshop Manual - Service
Procedures > Bookmark section "60 - Front Suspension" link "60.21.01 Air spring assembly"
3. Refer to Global Technical Reference (GTR) Range Rover (LM) Workshop Manual Section 60 - Front Suspension, operation 60.21.01 Air
spring assembly and replace the front air spring assembly.
DisclaimerLand Rover Range Rover Technical Service Bulletin # TECLM204007 Date: 060912
Wheels/Tires - Steering Wheel Vibration
No: LM204-007
Issue: 1
Date: 12 Sep 2006
THIS BULLETIN REPLACES TECHNICAL BULLETIN 60/02/03/NAS
SECTION: 204-04 WHEELS AND TIRES
Steering Wheel Vibration
AFFECTED VEHICLE RANGE:
Range Rover (LM)
VIN:
ALL
CONDITION SUMMARY:
STEERING VIBRATION FROM TIRE FLAT-SPOTTING AND RADIAL FORCE VARIATION
Situation:
This bulletin addresses concerns of a steering wheel vibration/steering shimmy identified on the initial vehicle preparation road test or from a
customer complaint. Tire flat-spots are a likely cause.
A customer may also complain of steering vibration or "shimmy" at moderate highway speeds (55mph). Sources of vibration/shimmy can be an
out-of-balance condition or Radial Force Variation (RFV) in the wheel-tire assemblies. Also the positioning/mounting of the wheels on the vehicle
can be a factor.
Action:
Carry out the Repair Procedure to correctly diagnose tire flat-spots and wheel balancing requirements.
In case of a customer complaint of vibration/shimmy on vehicles, follow the optimization procedures in this bulletin using a Hunter 9700/9712
balancing machine.
PARTS:
NOTE:
Correct two-part wheel weights are available from Wurth USA (800 987 8487). Wurth part numbers are provided below for information:
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Locally Sourced WURTH weight numbers:
TOOLS:
Hunter 970019712 wheel balance machine
To ensure that the wheel/tire assembly is balanced correctly, Land Rover recommends the use of a five fingered clamp to support the wheel and tire
assembly on the balance machine. (Figure 1)
Haweka 9700 hub to wheel adapter (Figure 2)
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.
NOTE:
Steps 1 to 5 of the procedure are part of the Vehicle Preparation process. No claim should be initiated if the performance of these steps at initial
vehicle preparation resolves the concern.
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DDW requires the use of causal part numbers.
Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
VEHICLE PREPARATION STEPS
NOTE:
Step 1 of the procedure is part of the Vehicle Preparation process. No claim should be initiated if the performance of this step at initial vehicle
preparation resolves the concern.
NOTE:
Until flat-spots are removed, significant shimmy may be present, even if the car has only stood overnight. A test drive is required to ensure
temporary tire flat spots are removed. For longer term flat-spots, a longer drive may be required. The test drive should be carried out on normal
open roads to allow the highest speed that speed limits and road/traffic conditions allow.
1. If the vehicle is undergoing initial vehicle preparation, perform the following as part of the test drive:
^ Refer to the Vehicle Preparation Manual and adjust the tire pressures to the recommended cold tire pressures.
^ Drive the vehicle for at least 15km (10 miles) before attempting to assess shimmy.
^ Assess the level of wheel vibration.
2. If a customer complaint is being resolved, perform the following:
^ Adjust the tire pressures to the recommended cold tire pressures.
^ Drive the vehicle for at least 15km (10 miles) before attempting to assess shimmy.
^ Assess the level of wheel vibration.
3. If the level of steering vibration is considered acceptable, no further action is required.
4. If the levels of vibration remain unacceptable, perform the "Balance Wheels" section below.
BALANCE WHEELS AS REQUIRED
1. Raise vehicle on the lift immediately on returning to the workshop, to avoid inducing further tire flat spots.
2. Remove all four road wheel and tire assemblies for balancing.
3. Inflate each tire to 2.5bar (36lbf/sq.in) +/- 0.1 bar (1lbft/sq.in).
NOTE:
For adhesive weights, use the attachment arm on the Hunter machine to ensure accurate weight positioning.
239
4. Refer to Figures 3, 4 and 5 for correct wheel fitting attachment to the balance machine and balance road wheel and tire assemblies until the
residual imbalance dynamic is minimized.
^ Target is 0g on each plane, maximum is inner 5g, outer 5g.
^ Use the "bulls-eye" balancing mode to minimize residual imbalance.
5. If tire road force variations (RFV) measuring is available, the road wheel and tire assembly should aim for a maximum of 60 Newton (6.1 kgf /
13.4 lbf) first harmonic RFV, 100 Newton (10.2 kgf/22.5 lbf) peak-to-peak.
6. If these levels cannot be achieved, perform the following:
^ Remove the tire.
^ Follow the match mounting procedure as detailed by the Hunter machine.
^ Mark the high point of 1st harmonic RFV on the tire (ideally also mark on the inside too, as a future reference).
^ Install the lowest 1st harmonic RFV units to the front.
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^ Print out the results of balance and force variation before and after, and attach to repair order.
NOTE:
If RFV equipment is not available and the tire has not been removed from the wheel and the RFV spot (red dot) is still visible this, should
be installed at the top.
7. The high-point of RFV should be marked, and the road wheel and tire assembly installed to the vehicle with the RFV high point at the top,
prior to the wheels being tightened. (Figure 6)
NOTE:
Nothing should be used to brace the wheel while tightening the nuts as this can disturb the match mounting.
8. Install all four road wheel and tire assemblies.
9. Tighten wheel nuts to 140Nm (103 lbf ft).
10. Lower the vehicle onto the lift.
11. Restore tire pressures to the recommended settings.
12. Drive the vehicle for approximately 7km (5 miles) carried out on normal roads and up to speeds of approximately 80 km/h (50 mph) to verify
correction of steering vibration.
DisclaimerLand Rover Range Rover Technical Service Bulletin # TEC7610036 Date: 060605
Body - Various Wind Noise Concerns
No: 76/10/03/NAS
*Issue: 6
Date: 05 June 2006*
Wind Noise Corrective Actions
*CHANGES MADE FOR ISSUE "6" ARE HIGHLIGHTED WITH GREY BACKGROUND AND NOTED BY ASTERISKS*.
AFFECTED VEHICLE RANGE:
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New Range Rover (LM)
See Individual Repairs
SITUATION
VARIOUS WIND NOISE LOCATIONS MAY REQUIRE CORRECTIVE ACTION
The customer may complain of wind noise appearing to come from a variety of locations:
* High pitched hiss or buzzing from the windshield
* Noise from the top of the windshield
* Whistle from front of vehicle when driven at highway speeds
* Hiss or leaking sound from A-pillar and side mirror area (above 40 mph (65 kph))
* Buzzing sound from central area of headliner or rear of vehicle
* High level noise from A-pillar area
RESOLUTION:
PERFORM INDIVIDUAL REPAIR PROCESSES FOR EACH SYMPTOM
Each of the specific problem areas has a unique repair to resolve the noise complaint. After investigation to determine the source of the sound,
perform the repair specific to that area.
PARTS INFORMATION:
Repair 1..........A HIGH-PITCHED HISS FROM THE WINDSHIELD
No parts required
Repair 2..........BUZZING FROM THE WINDSHIELD AT HIGHWAY SPEEDS
Polyurethane Sealant - Locally sourced
Repair 3..........NOISE FROM THE TOP CORNERS OF THE WINDSHIELD
No parts required
Repair 4..........HIGH-PITCHED WHISTLE NOISE FROM THE FRONT OF THE VEHICLE
XCH500020..........Rubber strip Qty 2 per vehicle
Repair 5..........HISS OR LEAKAGE NOISE AROUND THE 'A' PILLAR AND DOOR MIRROR
CTT500020..........Foam Pad Qty 2 per vehicle
Polyurethane Sealant - Locally sourced
Repair 6..........BUZZING SOUND FROM CENTER OF HEADLINER OR REAR OF VEHICLE
Polyurethane Sealant - Locally sourced
Repair 7..........HIGH LEVEL OF WIND NOISE FROM 'A' PILLAR AREA
79086L..........Black expanding clip Qty 8
DYA000040..........Grommet Qty 8
DYC500020..........Yellow clip Qty 8
Repair 8..........HISSING/FLUTTERING NOISE FROM THE REAR DOOR FIXED SIDE GLASS
Polyurethane Sealant - Locally sourced
*Repair 9..........WHISTLE NOISE FROM CENTER OF WINDSHIELD AT HIGHWAY SPEEDS
* MWC9832PMA..........Fir-tree fastener Qty 1*
Repairs 10 - 13..........VARIOUS WIND NOISES No parts required.
WARRANTY CLAIMS:
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Normal warranty policy and procedures apply. Material allowance is included in labor operation.
REPAIR PROCEDURE
REPAIR 1: ALL VEHICLES
A gap between the windshield trim and the roof causes a high-pitched hiss from the windshield at approximately 38 - 50mph (60-80km/h).
CAUTION:
The top trim piece of the windshield must be protected to prevent damage. A gap must not be created between the bottom edge of the trim strip
and the windshield.
1. Using a nylon block and rubber mallet, move the windshield top trim upwards to close the gap. (Figure 1, Inset A)
2. Align trim to the roof until a "touch" condition is achieved along the entire length of the trim. (Figure 1, Inset B)
REPAIR 2: ALL VEHICLES
A gap or bulge between the windshield lower trim piece and the windshield causes a buzzing from the windshield area at highway speeds.
1. Lift wipers away from the windshield for access.
2. Clean the windshield at the junction with the plenum seal along the entire length of the plenum seal.
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3. Filling all gaps completely, apply polyurethane sealant between the seal and the windshield along the entire length of the seal. (Figure 2)
4. Remove any excess sealant.
5. Position wipers onto the windshield.
REPAIR 3: ALL VEHICLES
A gap between the windshield and the roof molding causes noise from the top corners of the windshield. (Figure 3, Inset A)
NOTE: The roof molding must be set in the correct fore/aft position to achieve a flush fit.
NOTE: GTR lookup sequence is as follows: GTR Home > NAS > Service Information/ LM - New Range Rover/2003 (or as applicable)>
Workshop Manuals > Service Procedures > Bookmark "76-2 - Exterior Fittings (or as applicable)" Link "76.43.68 Roof Moulding (or as
applicable)"
1. Refer to GTR Workshop Manual section 76-2 - Exterior Fittings procedure 76.43.68 and remove the roof molding.
2. Install the molding, aligning the rear end of the molding with the rear edge of the roof.
REPAIR 4: UP TO VIN 3A106721
A gap between the direction indicator lamp and the fender causes a high-pitched whistle noise from the front of the vehicle at high speeds.
1. Refer to GTR Workshop Manual section 86-2 - Lighting procedure 86.40.29 and remove the Left Hand and Right Hand front directional lamp
assemblies.
2. Clean the fender area where the adhesive strip will be applied. (Figure 4)
3. Remove protective backing from the adhesive rubber strip and secure to the fender. (Figure 4)
4. Install directional assemblies.
REPAIR 5:* UP TO VIN 4A152789*
A noise path between the mirror and the 'A' pillar causes a hiss or leakage noise from around the 'A' pillar and door mirror area at speeds greater than
40mph (64km/h).
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NOTE: Noise may be present even if NO gap exists.
1. Lower both front windows.
2. Ease out approximately 200mm (8 inches) of the window channel seal to expose the door seal channel. (Arrowed in Figure 5)
CAUTION:
The foam must extend equidistant to either side of the angle and must not overhang on either side of the seal.
3. Center the foam (CTT500020) on the angle in the seal and stick it onto the back of the seal directly over the angle. (Shaded in Figure 6)
4. Carefully fit the window channel seal to the door.
5. Repeat for the opposite side.
6. Refer to Technical Information Bulletin 76/18/03/NAS and verify that the window 'one touch' mode is operating correctly.
7. If the window 'one touch' mode is NOT operating correctly, complete the following steps:
* Remove the 200mm (8 inches) of the window seal again to expose the seal channel. (Arrowed in Figure 5)
* Remove the foam pad inserted above.
* Wipe the surface surrounding the joint with alcohol. (Figure 7)
NOTE: The outer most corner of the joint must be completely sealed with sealant.
* Apply a small amount of sealant into the base of the angle and push the sealant firmly into the back of the channel. (Inset in Figure 7)
* Apply sealant until it starts to protrude from the hole at the top of the cheater panel.
* Wipe off excess sealant.
* Install the glass seal to the door.
8. Refer to Technical Information Bulletin 76/18/03/NAS and verify that the window 'one touch' mode is operating correctly.
REPAIR 6: *UP TO VIN 3A131067*
A gap between the 'E' pillar seal and the quarter glass can result in a buzzing sound from the rear of vehicle or center of the headlining.
1. Refer to GTR Workshop Manual section 76-2 - Exterior Fittings procedure 76.43.36 and remove the 'E' pillar trim.
2. Clean quarter glass and 'E' pillar trim.
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3. Apply a 2mm (3/32 in.) bead of sealant along the entire forward edge of the 'E' pillar trim seal. (Arrowed in Figure 8)
4. Carefully install the 'E' pillar trim.
5. Remove excess sealant from 'E' pillar trim seal and the quarter glass. (Figure 9)
6. Repeat procedure for the alternate side.
REPAIR 7: UP TO VIN 3A114820
A gap between the side trim and windshield or a rocking / loose side trim may result in a high level of wind noise from 'A' pillar area at highway
speeds.
NOTE: The noise is most likely due to the side trim having been previously removed for windshield replacement.
1. Refer to GTR Workshop Manual section 76-2-Exterior Fittings procedure 76.43.39 and remove the 'A' pillar windshield side trim.
2. Remove and discard the black clips from the trim and retaining inserts from the 'A' pillar. (Arrowed in Figure 10)
3. Install new yellow clips (DYC500020) to secure the trim to the front of the 'A' pillar.
4. Install new retaining inserts (DYA000040) into the 'A' pillar.
5. Install new expanding clips (79086L) into the trim piece.
6. Position the trim to the front of the 'A' pillar and secure using expanding clips.
REPAIR 8: *ALL VEHICLES*
The rear door fixed side glass is not sufficiently bonded to the door *or gaps* are present in the *bonding* causing a *hissing or fluttering* noise
from the top rear corner of the fixed door glass.
* 1. Apply tape around the interior perimeter of the fixed side door glass, ensuring a sufficient seal between the glass and surround molding, to
246
confirm the cause of the noise during a road test.
2. Remove the tape from the side door glass.
3. Refer to GTR Workshop Manual section 76-1 - Doors procedure 76.34.04 and remove the rear door trim casing for access.
4. Remove the fixed side glass surround trim.
5. Remove interior waist seal. (Figure 11)
NOTE: For the fixed side glass to be correctly bonded, all Body-In-White (BIW) clips around the periphery of the glass must be completely
covered by the bonding material. The bonding is not correct if there are any gaps in the bonding or if any BIW clips are visible. (Figure 12)
6. Visually inspect for correct bonding around the perimeter of the fixed side door glass. (Figure 13)
7. If the bonding material around the perimeter of the glass has any gaps or does not completely cover all Body-In-White (BIW) clips, apply
sufficient Polyurethane Sealant to fill any gaps and completely cover all BIW clips, ensuring that the sealant is hidden by the black band
around the glass edges.*
8. If the rear door fixed glass is not properly bonded, refer to GTR Workshop Manual section 76-1 - Doors procedure 76.31.31 and remove the
rear door fixed side glass.
9. Install the rear side door fixed glass following adhesive guidelines in the GTR Workshop Manual. (Figure 14)
REPAIR 9: ALL VEHICLES
A whistle noise is heard from the centre of the windshield at speeds in excess of 60mph (97km/h). The noise may be caused by airflow over the
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passenger side plenum drain tube opening. The plenum drain tube opening is divided into four quadrants.
1. Tape over plenum drain tube opening to verify cause of the noise.
* 2. Remove tape after road test.
3. Insert Fir-tree fastener (MWC9832PMA) into the in-board, front quadrant of the drain tube opening. (Figure 15)*
REPAIR 10: ALL VEHICLES WITH SUNROOF
A general wind noise is heard from the front leading edge of the sunroof when traveling in excess of 50mph (80km/h). The likely cause is poor
sunroof alignment profile.
1. Tape the leading edge of the sunroof to verify cause of the noise.
2. Remove tape after road test.
NOTE: GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LM - New Range Rover/2003 > Workshop Manuals > Range Rover - Workshop Manual - Service
Procedures > Bookmark "76-6 - Sunroof" > Link "76.84.82 Sunroof - align to roof panel & adjust"
3. Refer to GTR section 76.84.82 and perform sunroof adjustment and alignment to roof panel.
REPAIR 11: ALL VEHICLES
A whistle is heard from the lower windshield area at speeds in excess of 50mph (80km/h) only when the recirculation damper is shut. The noise is
likely to be caused by a trapped foot well lamp wire in the recirculation "snail shell" housing.
NOTE: In the event of a concern of a noise from behind the instrument panel when the Heating Ventilation Air Conditioning (HVAC) is in
recirculation or automatic mode, evident at road speeds of above 60mph (100km/h), refer to Technical Bulletin 82/01/05/NAS - Range Rover
(LM) - Noise From HVAC System.
1. Reproduce the complaint during a test drive and cycle in and out of recirculation mode to confirm the suspected cause of the complaint.
2. Remove the pollen filter to access snail shell housing and free the trapped wire. (Figure 16)
REPAIR 12: ALL VEHICLES
A general wind noise is heard from the top of the B-pillar area at speeds in excess of 30mph (48km/h). The noise may be caused by the front door
glass being set too far forward.
1. Close the affected window completely.
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2. Determine if the top corner radius of the window glass, adjacent to the B-Pillar, is visible indicating that the window is set too far forward.
(Figure 17)
3. If the corner is not visible, use a blunt plastic implement to gently probe the top rear edge of the seal to assess the overlap of the seal over the
glass. (Figure 18)
4. If the glass can be felt, it is unlikely that improper window glass alignment is the cause of the complaint.
5. If the glass cannot be felt, lower the window by approximately 260mm (10 inches), to position window glass for access to the securing torx
bolts. (Figure 19)
NOTE: GTR lookup sequence is as follows: GTR Home > NAS > Service Information/ LM - New Range Rover/2003 > Workshop Manuals
> Range Rover - Workshop Manual - Service Procedures > Bookmark "76-1 Doors" > Link "76.34.01 Trim casing - front door"
6. Refer to GTR Workshop Manual section 76.34.01 and remove the front door casing for access only.
7. Partially release the plastic sheet and temporarily secure up and out of the way to gain access to torx bolts securing glass. (Figure 20)
NOTE: If attempts are made to move the glass rearwards without lifting the glass out of the clamps, the glass may return to original position
due to elasticity of the rubber clamps.
8. Loosen torx bolts securing glass.
9. Lift glass out of clamps and move glass rearward by the amount of the observed gap at initial inspection. (Figure 21)
249
10. Lower glass back into the clamps.
11. Secure front glass torx bolts to 10 Nm (7 lbf-ft).
12. Temporarily connect the harness to confirm operation of window glass and ensure window glass has been set correctly and can raise fully.
(Figure 22)
13. Install partially removed plastic sheet and verify that a good seal to the door panel has been achieved.
14. Refer to GTR Workshop Manual section 76.34.01 and install the front door casing.
15. Verify correct operation of door mounted switchpack and speakers after the door casing is installed.
REPAIR 13: ALL VEHICLES
A general wind noise and whistle from top of windshield at speeds in excess of 50mph (80km/h) may be heard. The noise could be caused by the
leading edge of the roof rail finisher lifting.
1. Unclip roof rail finisher, position the finisher correctly, and reinstall the clip. (Figure 23)
DisclaimerLand Rover Range Rover Technical Service Bulletin # TECLTB00061 Date: 070713
Body - Exterior Door Handle Replacement
No.: LTB00061
Issue: 1
Date: 13 July 2007
SECTION: 501-14
Exterior Door Grab Handle - Available as Spare Part
250
AFFECTED VEHICLE RANGE:
Range Rover (LM) VIN: ALL
CONDITION SUMMARY:
GRAB HANDLE AVAILABILITY PERMITS RELEASE HANDLE ASSEMBLY REPAIR
Situation:
Prior to the grab handle kit being available, if a concern existed with the exterior door grab handle the complete release handle mechanism assembly
had to be replaced. Retailers are advised that the exterior door grab handle is now available as a serviceable part.
Action:
If a concern exists with the exterior door grab handle, install the grab handle kit, following the Repair Procedure outlined below. Replacement of the
complete handle mechanism assembly is no longer required for grab handle repairs.
PARTS
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.
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
REPAIR PROCEDURE
GRAB HANDLE REPLACEMENT
NOTE:
Global Technical Reference (GTR) lookup sequence is as follows:
GTR Home> NAS > LM - Range Rover> Service Information/2007 > Workshop Manuals> Bookmark "Body and Paint/501-14 Handles,
Locks Latches and Entry Systems" LINK "Exterior Front Door Handle (76.58.28)"
1. Refer to GTR Section 501-14 and remove the front or rear exterior door handle mechanism as required.
CAUTION:
Upon reassembly the orientation of the return spring must be the same.
2. Observe the orientation of the return spring for later assembly.
WARNING:
Preloaded return spring could cause injury if not properly captured during pivot pin removal.
251
3. Remove the mass balance assembly as follows: (Figure 1)
^ Remove and discard the pivot pin retaining clip.
^ Remove the mass balance pivot pin.
^ Remove the return spring.
4. Remove the exterior door handle pivot pin and remove the grab handle. (Figure 2)
5. Install the exterior door handle pivot pin to the new door grab handle and door handle assembly.
CAUTION:
For proper operation the return spring must be properly oriented.
6. Verify that the return spring is oriented to the correct position as noted in step 2 above.
7. Install the mass balance assembly as follows:
^ Install the return spring.
^ Install the mass balance pivot pin.
252
^ Install the new mass balance pivot spring retaining clip. (Figure 3)
8. Lubricate the mass balance assembly contact area. (Figure 4)
9. Refer to GTR Workshop Manual section: 501-14 and install the repaired exterior door handle mechanism.
Disclaimer
Land Rover Range Rover Technical Service Bulletin # TECLTB001832 Date: 090107
Engine - Aluminum Component Thread Repair
No: LTB00183
Issue: 2
Date: 07 JAN 2009
ISSUE '2' CHANGES ARE HIGHLIGHTED IN GRAY.
SECTION: 303
Aluminum Engine Components Thread Repair
253
AFFECTED VEHICLE RANGE
CONDITION SUMMARY:
Situation:
Where applicable, damaged threads of aluminum engine components may now be repaired in lieu of replacing the affected component by using a
'thread repair kit' such as Heli-Coil(R).
Action:
In the event it becomes necessary to repair damaged threads, follow the instructions provided with the thread repair kit.
PARTS:
Heli-Coil(R) Thread Repair Kit (or similar) Sourced Locally
WARRANTY
REPAIR PROCEDURE
1. Repair damaged threads by following the instructions supplied with the thread repair kit.
Land Rover Range Rover Technical Service Bulletin # TECLTB00248 Date: 091217
Suspension - Correct Ball Joint Splitter Usage
No: LTB00248
Issue: 1
Date: 17 DEC 2009
SECTION: 204
Correct Procedure for Ball Joint Splitter Use
AFFECTED VEHICLE RANGE:
All
CONDITION SUMMARY:
254
Situation:
For information only, informing the Authorized Retailers of the correct procedure for using the Ball Joint Splitter (tool number 205-754A).
Action:
In the event it becomes necessary to use the Ball Joint Splitter (205-754A), refer to the Service Procedure outlined below.
PARTS:
No parts necessary; information only
TOOLS:
205-754A .................Ball joint splitter
Normal warranty policy and procedures apply.
SERVICE PROCEDURE
CAUTION:
Do not use air tools.
1. Ensure ball joint splitter (205-754A) is correctly fitted to the ball joint.
^ To allow for equal loads during operation, ensure the ball joint splitter is set so the top and bottom sections are parallel. ((4) Figure 1)
CAUTION:
During operation, the ball joint may be displaced from the vertical link and the ball joint splitter may be separated from the ball joint.
2. Tighten the ball joint splitter forcing screw to 60 Nm (45 lbf ft). ((3) Figure 1)
CAUTION:
During operation, the ball joint may be displaced from the vertical link and the ball joint splitter may be separated from the ball joint.
^ If the ball joint has not been displaced, use a suitable tool and strike the top of the ball joint splitter ((1) Figure 1), introducing a shock to displace
