Recall - Power Assist Steering (PAS) Pump Replacement
No: D385Ref:
Issue: 1
Date: 10/15/99
RECALL
PAS Pump Pulley Improvements
AFFECTED VEHICLE RANGE:
Range Rover (LP) XA400940 to XA427315
Vehicles with Bosch Engine Management only
SITUATION:
PAS PUMP PULLEY FAILURE
The loading condition present on the Range Rover power assist pump pulley can cause the joint between the pulley and its center hub to fail. In the event of a pulley failure, the serpentine drive belt will also be subjected to damage resulting in loss of engine auxiliary functions (power assisted steering, electrical charging system and vehicle cooling). Should the serpentine belt fail, the alternator warning light will illuminate on the instrument panel, the message center will indicate "Alternator Fault" and an audible alarm (beep) will sound.
RESOLUTION:
REPLACE PAS PUMP/PULLEY ASSEMBLY
All Range Rover vehicles within the specified VIN range require replacement of the PAS pump/pulley assembly.
All affected vehicles currently held in retailer inventory as new or used vehicles must be repaired prior to sale.
PARTS INFORMATION:
CAUTION:
Retailer inventory of PAS pump QVB101300 may NOT be used to repair a vehicle. Return QVB101300 pumps to Land Rover using a PAF referencing this bulletin.
LRN0002LABEL Campaign label Qty 1
QVB000040K PAS Pump Qty 1
ANR2377 PAS hose clip Qty 1
LRNA241C PAS hose clip Alternate
Locally Source:
Power Steering Fluid Quantity as required - 1 pint allowed for
TOOLS
LRA-99-001 Standard Jaw Pinchers (Model 1089)
Locally sourced Vernier Calipers
WARRANTY CLAIMS:
D385 Option 1 0.15 hrs
Inspect PAS Pump pulley and install label
D385 Option 2 0.95 hrs
Inspect and remove PAS pump/pulley assembly and replace with new pump/pulley assembly QVB000040K
Normal warranty policy and procedures apply
REPAIR PROCEDURE
INSPECT PAS PUMP PULLEY
NOTE:
Inspection of the PAS pump pulley is required to determine if the new configuration pump/pulley assembly has been installed as the result of a previous repair. When a new configuration pump/pulley assembly is determined to have been installed, replacement is NOT required.
1. Refer to Figure 1 and inspect PAS pump pulley as follows:
^ Grasp the plastic belt cover at the lower edge on driver's side of vehicle.
^ Pull and bend cover upward and forward to reveal center of PAS pump pulley.
^ Using calipers, measure size of raised boss at pump pulley center. (Figure 1)
2. If the front center boss is 38mm (1.5 inches) in diameter, the pump/pulley assembly must be replaced. Go to "Remove and Replace PAS Pump" section.
NOTE:
Inspection of the back side of the pulley will reveal a large 60mm (2.36 inches) diameter reinforcing boss. This is a convenient double check of the front boss measurement process and confirms that the pulley is the latest configuration.
3. If the front center boss is 30 mm (1.18 inches) in diameter, the pump/pulley assembly is the latest configuration. Go to "Recall Campaign Label Installation" section and install label.
REMOVE AND REPLACE PAS PUMP/PULLEY
WARNING:
Ensure that PAS fluid outflow from repair or bleeding process is captured in a container and that any spillage is wiped from all engine surfaces to avoid possible flaring of fluid upon engine start-up.
1. Refer to WSM Section 12.41.01.99 and remove the belt cover and the serpentine belt.
2. Refer to WSM Section 57.20.14 and remove the PAS pump/pulley assembly from the vehicle as follows:
^ Place container under vehicle to capture PAS fluid.
^ Disconnect banjo bolt fitting and retain seal washers for re-use.
^ Remove and discard return pipe hose clamp.
^ Disconnect return hose.
^ Remove pump retaining bolts and remove pump.
3. Install new PAS pump/pulley assembly (QVB000040K) following WSM procedure as follows:
^ Clean all mounting surfaces and locating dowel.
^ Fit pump/pulley assembly, install two mounting bolts and torque to 25 Nm (18 lbf.ft.).
^ Install new clamp over low pressure feed hose and fit hose.
^ Crimp hose clamp using special tool LRA-99-001.
^ Clean high-pressure banjo fitting and bolt.
^ Verify banjo seal washers are in position on either side of the banjo fitting.
^ Install banjo fitting with bolt and washers.
^ Torque banjo bolt to 25Nm (18 lbf.ft.).
4. Install serpentine belt following WSM procedure.
5. Install belt cover.
6. Refer to WSM Section 57.15.02 and bleed PAS system, observing all warnings and cautions.
RECALL CAMPAIGN LABEL INSTALLATION
CAUTION:
Do not touch the exposed label adhesive with your fingers. The bond will be diminished if contaminated prior to application.
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 Recall label (LRNOOO2LABEL) 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 "D385"
^ 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 cross member.
4. Roll the label with the special roller tool to ensure that the adhesive makes continuous contact with the cross member surface.