Campaign - Engine Thermostat Canister Replacement
No: H202* Ref: H389
Issue: 2
Date: 04/14/00 *
SERVICE ACTION
Discovery Series II Overheating at Idle
Updated information is shown by asterisks.
AFFECTED VEHICLE RANGE:
DISCOVERY Series II (LT) XA213405 to YA250696
(XA9... Series vehicles are NOT affected)
Updated information is shown by asterisks.
SITUATION:
TENDENCY TO OVERHEAT AT IDLE
Vehicles sitting at idle or traveling in very slow traffic for an extended period (45 minutes) may experience overheating even in moderate temperatures. The thermostat may not open due to cold water leaking past the thermostat diaphragm, cooling the sensing bulb. This condition does not allow the thermostat to reach sufficient temperature to open properly.
RESOLUTION:
REPLACE THERMOSTAT CANISTER ASSEMBLY
NOTE:
This TIB supersedes TIB H389. Vehicles that have been repaired using the procedures in H389 are EXCLUDED from the vehicle population of Service Action H202. Land Rover will NOT pay for the replacement of a thermostat that has been previously repaired using the H389 method.
Installation of a new-specification thermostat canister, identified by a colored dot marking, will correct an overheating problem. The new canisters correct the thermostat flow-by condition and permit opening at the normal temperature range.
PARTS INFORMATION:
*NOTE:
Thermostat availability may dictate a repair using the procedures originally specified in H389. In such cases for vehicles within the affected VIN range, refer to the alternative repair procedure outlined in the "Repair Procedure" section and claim H202 Option 5.*
LRN0002LABEL Campaign label Qty 1
PEM100990K Thermostat Qty 1 (Correct stock marked by COLORED dot)
*NOTE:
Kem Krest Inc. specializes in the supply of automotive chemicals. Land Rover has arranged for its retailers to be able to obtain Loctite(R) 603 through Kem Krest.
Source through KEM KREST Ordering phone: 1 800 582 7953
^ Loctite(R) 603 Retaining Compound Loctite product number 21440 (10 ml)
^ Loctite(R) 603 Retaining Compound Loctite product number 21441 (50 ml)
^ Loctite(R) Applicator (2 with initial order) Loctite product number 97223
Locally sourced:
Yellow Touch-up paint*
WARRANTY CLAIMS:
H202 (Option 1) Time 0.20 hrs.
Inspect for previous H389 repair (yellow "X" on thermostat)
H202 (Option 2) Time 0.85 hrs.
Replace thermostat canister assembly
Material Allowance is incorporated into the time allowance for repair
H202 (Option 3) Valid for repairs performed before 13 Jan 2000
H389 (Option 1) Time 0.30 hrs.
Perform idle inspection
H202 (Option 4) Valid for repairs performed before 13 Jan 2000
H389 (Option 2) Time 1.30 hrs.
Perform idle inspection, remove, repair and install thermostat canister assembly
Material Allowance is incorporated into the time allowance for repair
* H202 (Option 5) Time 1.30 hrs.
Remove thermostat, repair and install repaired assembly. Material Allowance is incorporated into the time allowance for repair*
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
INSPECTION FOR H389 ACTION
1. Inspect vehicle to determine if previous repair has been completed.
^ If thermostat canister is marked by yellow "X" then repair has been made under Service Action H389. (Figure 1)
^ If corrected new thermostat (PEM100990) has been installed, thermostat will have a colored dot marking.
^ Determine also if Campaign Label for H389 has been placed on vehicle.
2. If Service Action H389 has been performed, scribe "H202" on the installed campaign label. No further action is required.
*3. If PEM100990K is available for repair, perform "REMOVE AND INSTALL THERMOSTAT" section of this TIB and claim Option 2.
4. If thermostat assembly is not available, perform the "REMOVE, REPAIR AND INSTALL THERMOSTAT" section of this TIB and claim Option 5.*
REMOVE AND INSTALL THERMOSTAT
1. Refer to the WSM Section 26.45.09 and remove thermostat canister assembly from the vehicle. (Figure 1)
2. Install the new thermostat canister (PEM100990K).
CAUTION:
The cooling system must be thoroughly and completely bled.
3. Refer to the WSM Section 26.10.01 and bleed the cooling system thoroughly.
*REMOVE, REPAIR AND INSTALL THERMOSTAT
1. Refer to the WSM Section 26.45.09 and remove thermostat canister assembly from the vehicle.
2. Remove as much coolant from the thermostat canister assembly as possible.
3. Soak and then rinse the thermostat canister assembly in very hot water until all residual coolant is removed.
4. Use compressed air to remove all water from the thermostat canister assembly and allow to thoroughly dry.
CAUTION:
The thermostat canister assembly must be completely dry before continuing.
5. Verify that the thermostat canister assembly is completely dry.
CAUTION:
When applying Loctite 603 ensure that the following care points are observed:
^ Apply Loctite only to the specified location. The rubber seal around the diaphragm must be carefully avoided.
^ Loctite must not leak through to the other side of the thermostat.
^ The Loctite must be allowed to cure for 3 hours before reinstalling the thermostat canister assembly in the vehicle.
6. Modify the thermostat canister assembly as follows:
^ Rest the thermostat canister on a flat surface with the single outlet end upward.
^ Apply Loctite 603 in the crevice between the brass bulb and the black diaphragm using the applicator. (Figure 2)
7. With the single outlet side still facing up, allow the Loctite to cure for 3 hours.
8. After the Loctite has cured, press on the spring loaded pressure valve located on the 2-outlet side of the thermostat canister assembly to verify that it still compresses and returns properly.
9. If thermostat spring will not compress, replace thermostat canister assembly with new unit.
10. Install the thermostat canister in the vehicle and mark the exterior with a yellow "X" to indicate that the repair has been completed. (Figure 1)
CAUTION:
The cooling system must be thoroughly and completely bled.
11. Refer to the WSM Section 26.10.01 and bleed the cooling system thoroughly.*
INSTALL CAMPAIGN LABEL
NOTE:
Campaign labels may have multiple Campaign numbers written on them if multiple campaigns are performed at the same time.
1. When all specified repairs have been accomplished, prepare the campaign label (LRN0002LABEL) as follows:
a) Place the label on a hard surface.
b) Use a ballpoint pen to neatly write/scribe in the bare aluminum areas of the label the following information:
^ Service Action code "H202"
^ Your retailer code
^ The date of repair
2. Clean all grease and dirt from the radiator support member.
3. Peel the completed campaign label from the backing paper and position it on the cleaned area of the support member.
4. Roll the label with the special roller tool to ensure that the adhesive makes continuous contact with the support member surface.