Campaign - Catalytic Converter Warranty Extension
No.: LTB00224Issue: 3
Date: 14 DEC 2009
ISSUE '3' CHANGES ARE HIGHLIGHTED ASTERISKS
SECTION: 309
Extended Warranty Program - Exhaust Catalyst Housing Cracking
AFFECTED VEHICLE RANGE:
CONDITION SUMMARY:
Situation:
A concern has been identified with the housing of some catalytic converters fitted to 2003 - 2005 model year Range Rover vehicles. The catalytic converter housing may crack or leak as a result of poor welding during the manufacturing process. This crack could result in increased exhaust sound or the illumination of the 'check engine' lamp, with the possibility of DTCs stored.
Action:
Land Rover has taken the decision to extend the emissions warranty on the affected vehicles for this component failure mode only from 8 years / 80,000 miles (130,000Km) to 11 years / 120,000 miles (193,000Km) from the date of first registration and to replace the catalytic converter if the housing cracks and / or leaks as a result of the manufacturing process failure described above. Affected vehicle owners will notified of this change to their vehicle warranty with an Owner Notification Letter beginning 30 June 2009. Refer to the Repair Procedure outlined below to inspect the catalytic converters for cracks / leaks and, if necessary, to replace the catalytic converter(s) as part of this program as a consequence of the manufacturing process failure detailed above.
PARTS:
TOOLS:
IDS with latest DVD; software first available on DVD117 Patch File 5 Midtronics PSC-550 Vehicle Power Supply
Refer to Workshop Manual (GTR) for any required special tools
WARRANTY:
NOTE:
The Warranty information is only applicable for repairs to vehicles outside the normal 8-year I 80,000 mile (130,000Km) Emission Warranty and included in this program. For vehicles within the Emission Warranty, normal Warranty policies and procedures apply.
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.
Extended Warranty Program claims should be submitted quoting program code Q058, together with the relevant Option Code. As Option Codes are used, there is no requirement for you to enter parts or labor; these are provided for information only. The Option Code that allows for the drive in I drive out allowance can only be claimed if the vehicle is brought back into the workshop for this action alone to be undertaken.
CUSTOMER REIMBURSEMENT / OXYGEN SENSOR CLAIM PROCESS
If a customer has indicated that they have already paid to replace the exhaust catalyst as a result of this weld failure prior to 30 June 2009 as a normal retail repair (vehicle outside warranty period), a copy of the repair invoice must be produced. The Retailer must reimburse the customer and a claim for recovery of this cost should be made using the related damage procedure. Refer to Service Bulletin *SWA09-08 / SWA09-08C* for additional administration details.
If the oxygen sensors or sealing washers are damaged during the renewal of the catalytic converters, claims for oxygen sensor replacement may be made using the related damages procedure.
Supplementary claims for related damages can only be made once the Extended Warranty Program claim has been paid / accepted.
Claims should be submitted quoting Program Code Q058 and by clicking the Related Damage radio button on the claim submission screen.
The Warranty Claim should be submitted using Option Code X and entering the part numbers to be reimbursed.
A copy of the invoice must be attached to the repair order for Warranty audit purposes.
A brief comment should be entered in the Technician Comments field on the claim to itemize and explain the charges.
Only vehicles eligible for Extended Warranty Program Q058 are included in this process. Normal warranty policy and procedures apply.
REPAIR PROCEDURE
INSPECT CATALYTIC CONVERTERS
1. Inspect both left and right-hand catalytic converters for cracks and leaks, paying particular attention to the weld joints. (Figure 1)
^ If the catalytic converter(s) is leaking or cracked as a result of a weld failure, continue to 'REPLACE CATALYTIC CONVERTER(S)'.
NOTE:
Normal warranty policy and procedures apply.
If no cracks or leaks are evident, return vehicle to the customer; if necessary, diagnose / repair any other customer concerns.
REPLACE CATALYTIC CONVERTER(S)
NOTE:
Global Technical Reference (GTR) lookup sequence is as follows:
GTR Home > NAS > LM - New Range Rover > Service Information > Model Year > Workshop Manual > 17-2 - Emission Control - V8 > 17.50.01 Catalytic Converter
1. Refer to Workshop Manual (GTR) section 17-2 Emission Control V8 (17.50.01) to replace the cracked / leaking catalytic converter(s).
2. Inspect the oxygen sensor sealing washers for damage.
^ If the sealing washers do not show signs of damage other than the normal compression of the washer from the original installation, reuse the original oxygen sensor(s).
^ If the sealing washers do show signs of damage other than normal compression of the washer from the original installation, replace the affected oxygen sensor(s).
3. If engine Malfunction Indicator Lamp (MIL) is illuminated, continue to 'CLEAR DIAGNOSTIC TROUBLE CODES'.
4. If engine Malfunction Indicator Lamp (MIL) is not illuminated, return vehicle to customer; if necessary, diagnose / repair any other customer concerns.
CLEAR DIAGNOSTIC TROUBLE CODES
CAUTION:
A Midtronics PSC-550 Vehicle Power Supply must be connected to the vehicle battery during IDS diagnosis / module programming.
1. Connect the Midtronics PSC-550 Vehicle Power Supply to the vehicle battery.
NOTE:
IDS must be loaded with software release DVD117 Patch File 5 or later.
2. Connect the IDS to the vehicle and begin a new diagnostic session by entering the correct VIN for the current vehicle.
3. Follow the IDS prompts to read the vehicle configuration.
4. Select Yes when prompted 'Do you wish to read diagnostic trouble codes?'
5. Select 'tick' to continue, following all on-screen instructions to complete this task.
6. Exit the current session.
7. Disconnect IDS and the Midtronics PSC-550 Vehicle Power Supply from the vehicle.
8. Refer to Service Bulletin SWA09-06 and perform a Long Drive Cycle (Road Test).
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