Cooling System - Revised Coolant Reservoir Replacement
No.: LM303-008Issue: 1
Date: June 12, 2006
SECTION: 303-03
Engine Coolant Expansion Tank Replacement Procedure Change
AFFECTED VEHICLE RANGE:
New Range Rover (LM) VIN: 3A101029 to 5A194480
CONDITION SUMMARY:
NEW SERVICE PROCEDURE TO REMOVE AND INSTALL ENGINE COOLANT EXPANSION TANK
NOTE:
Associated repairs that require the new coolant expansion tank removal and installation workshop procedures will change accordingly. The relevant Range Rover GTR Workshop Manual Sections will be updated at the next available opportunity.
Situation:
Land Rover engineering has studied the service process for removing and installing the coolant expansion tank resulting in significant procedure changes. The revised and improved procedures are detailed in the appended Workshop Manual section. A change to clamping the lower coolant hose eliminates the requirement to perform a full coolant system bleed operation.
Action:
Should it become necessary to remove an engine coolant expansion tank on a New Range Rover, in the specified VIN range, refer to the service procedure detailed in this bulletin.
PARTS:
No parts required.
Procedure change information purposes only.
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.
The original SRO 26.15.01 repair time of 0.50 hrs has been updated with new time of 0.30 hrs.
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
SERVICE PROCEDURE
REMOVE ENGINE COOLANT EXPANSION TANK
WARNING:
Care must be taken to prevent injury from escaping hot steam or coolant. The coolant expansion tank filler cap must not be removed while the system is hot.
1. Ensure the engine coolant has cooled sufficiently.
2. Slowly remove the coolant expansion tank filler cap to release the cooling system pressure.
CAUTION:
Clean plugs must always be used to protect open connections from contamination.
CAUTION:
Engine coolant will damage paint finished surfaces. Immediately remove any spilled coolant and clean area with water.
3. Release the hose clip on the upper hose of the coolant expansion tank. (Arrowed in Figure 1)
4. Disconnect the upper hose from the expansion tank.
5. Install a suitable hose clamp onto the lower hose of the coolant expansion tank to prevent coolant leakage and air ingress. (Figure 2)
6. Position a suitable coolant catch container beneath the lower hose and expansion tank outlet tube to collect any coolant.
7. Release the hose clip on the lower hose of the coolant expansion tank. (Arrowed in Figure 2)
8. Disconnect the lower coolant hose from the expansion tank.
9. Ensure all residual coolant has stopped dripping from the hose and tank outlet tube.
10. Carefully remove the container from the vehicle.
11. Remove the two nuts securing the expansion tank to the body. (Arrowed in Figure 3)
12. Position the expansion tank aside.
13. Disconnect the electrical connector from the expansion tank low-level sensor.
NOTE:
The coolant expansion tank is now sufficiently disconnected for access only.
14. If coolant expansion tank replacement is required complete removal as follows:
^ Remove the coolant expansion tank.
^ Remove coolant low-level sensor for reuse. (Arrowed in Figure 4)
INSTALL ENGINE COOLANT EXPANSION TANK
1. If a new expansion tank is being installed, install the original low-level sensor to the new expansion tank.
2. Position the expansion tank at the inner body panel and connect the electrical connector to the coolant low-level sensor. (Arrowed in Figure 4)
3. Install the expansion tank to the body and tighten the two retaining nuts. (Arrowed in Figure 3)
4. Connect the lower coolant hose to the expansion tank and secure with the hose clip. (Arrowed in Figure 2)
5. Remove the hose clamp from the lower hose.
6. Connect the upper coolant hose to the expansion tank and secure with hose clip. (Arrowed in Figure 1)
7. Fill the expansion tank to the maximum level with proper coolant mix.
8. Verify no leaks are present at the hose connections.
Disclaimer