Campaign - SAI Hose Inspection/Replacement
No: SB143Ref:
Issue: 1
Date: 11/07/03
SERVICE ACTION
Verify Secondary Air System Hose Installation
AFFECTED VEHICLE RANGE:
Discovery Series II (LT) 3A767790 to 4A831321
Build Date 26 February 2002 to 28 August 2003
SITUATION:
OUT OF SPECIFICATION TUBING PERMITS HOSE CLAMP MOVEMENT
A limited number of vehicles within the above VIN range may have Secondary Air Injection (SAI) stainless steel pipe with an incorrectly positioned hose retaining bead. The SAI flexible hose retaining clamps may not grip the hose properly on affected vehicle and may become loose or slide off onto the stainless steel SAI pipe.
RESOLUTION:
INSPECT THE HOSE INSTALLATION
NOTE:
This Service Action is for un-sold vehicles held in Retailer inventory only.
Prior to customer delivery a visual inspection on all 2003 and 2004 model year vehicles, within the above VIN range, is to be conducted to determine if the retaining clamps are positioned correctly on the hose. If the retaining clamps have loosened or moved, replace the left hand and right hand SAI flexible hoses with the longer flexible hoses.
PARTS INFORMATION:
WAH500070K SAI hose kit Qty 1 (Contains two hoses)
LRN0002LABEL Campaign Label Qty 1 (NOTE: Sold in quantity pack of 100)
AS400 WARRANTY CLAIMS:
H143 (Option A) Time 0.10 hrs.
Inspect SAI hoses
H143 (Option B) Time 0.30 hrs.
Inspect and replace SAI hoses - Includes Drive-in/Drive-out time
DDW WARRANTY CLAIMS:
Warranty claims should be submitted quoting program code B143 together with the option code. This will result in payment of stated time and where applicable parts/miscellaneous expense.
The SRO information listed in the Table has been included for information only. Do not enter the SRO onto the claim.
The options that allow for drive in/drive out may only be claimed when the vehicle has been brought into the workshop for this action alone to be undertaken.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
INSPECT SAI HOSE FOR CLAMP POSITION
NOTE:
It is important to verify that the unsold vehicle is subject to this Service Action and has not had the repair performed at the Port of Entry.
1. Verify that the vehicle is subject to the Service Action.
2. Open the hood and install fender protection covers.
3. Inspect the LH and RH SAI flexible hose retaining clamps and verify that they are in the correct position.
^ Check that the hose retaining clamps (see Figure 1 and Figure 2) are not loose or fallen off the hose onto the stainless steel SAI pipe.
^ Ensure that the hose clamp is at least 3 mm (1/8 inch) from the end of the flexible hose (Arrowed in Figure 3).
Verify that the clamp is installed above the retaining lip in the stainless steel SAI pipe. (Figure 3)
4. If either of the SAI flexible hose retaining clamps is in the wrong position or is loose, replace both hoses.
REPLACE HOSES AND CLAMPS WITHOUT PROPER FIT
1. Release the battery cover fasteners and remove the cover.
2. Disconnect the battery ground lead.
CAUTION:
Special care should be taken to ensure that the HT lead routing is minimally disturbance in this procedure.
CAUTION:
The stainless steel SAI pipe must be supported during removal of the SAI flexible hose, to prevent distortion to the pipe.
3. Remove the SAI hose from one side of the vehicle as follows:
^ Support the stainless steel SAI pipe.
^ Release both SAI flexible hose retaining clamps.
^ Disconnect and remove the SAI flexible hose.
^ Clean component mating surfaces.
^ Position the removed retaining clamps onto the new SAI flexible hose.
^ Install the new SAI flexible hose fully onto the air pump and onto the SAI pipe.
NOTE:
The hose retaining clamp must be 3 mm (1/8 in) from the end off the flexible hose, The flexible hose must be installed over the retaining lip on the stainless steel SAI pipe.
^ Ensure that the hose retaining clamp is 3 mm (1/8 inch) from the end off the flexible hose, and that the flexible hose is installed over the stainless steel SAI pipe retaining lip. (Figure 3)
^ Tighten both SAI flexible hose retaining clamps to 3 Nm (26.5 lbf.in).
CAUTION:
The LH and RH SAI hoses must be replaced as part of this Service Action when the inspection has revealed the need to replace either hose.
4. Go to Step 3 and perform the SAI hose replacement procedure on the alternate side of the vehicle.
5. Connect the battery ground lead.
6. Install the battery cover and install the fasteners.
7. Remove the fender protection covers and close the hood.
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 Campaign code "B143"
^ 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.