Recall - Throttle Cable Inspection/Replacement
No: D274Ref:
Issue: 1
Date: 03/05/02
RECALL
Throttle Cable Damage Inspection
AFFECTED VEHICLE RANGE:
Discovery Series II (LT) XA900000 - XA907214
XA200253 - 1A299999
1A700000 - 2A758930
SITUATION:
POSSIBLE THROTTLE CABLE DAMAGE
Land Rover has determined that a fault that affects vehicle safety exists with the throttle cable on Discovery Series II vehicles within the affected VIN range.
The accelerator cable can become kinked during vehicle assembly operations, which results in a wear point in the cable that can lead to breakage of the interior cable strands. This could result in the throttle being stuck in the open position.
RESOLUTION:
INSPECT AND IF INDICATED REPLACE CABLE
Vehicles in the affected VIN range are to have the throttle cable inspected for kinks or damage. If a kink or damage is found, replace the cable with a new part.
PARTS INFORMATION:
SBB103820K Throttle cable Qty 1
BNP2236L 0-ring/grommet Qty 1 (part of material allowance, only as required)
WARRANTY CLAIMS:
NOTE:
If this work is being completed in conjunction with D263, it is important that the correct "Option Code" be selected for warranty claim submission.
D274 (Option 1) Time 0.10 hrs
Inspect throttle cable (in conjunction with D263)
D274 (Option 2) Time 0.20 hrs
Inspect throttle cable and replace (in conjunction with D263)
D274 (Option 3) Time 0.30 hrs
Inspect throttle cable
D274 (Option 4) Time 0.40 hrs
Inspect throttle cable and replace
Normal warranty policy and procedures apply.
Material allowance and drive-in/drive-out time is included in labor operation.
REPAIR PROCEDURE
INSPECT AND IF NECESSARY REPLACE CABLE
1. Clean the throttle cable to permit careful inspection.
2. Locate the throttle cable fitting in the bulkhead (Figure 1).
CAUTION:
Care must be taken to ensure no damage is done to the throttle cable 0-ring/grommet during the inspection.
3. Twist the fitting to release the cable from the bulkhead.
4. Disconnect the cable from the operating lever at the throttle body.
5. Carefully inspect the throttle cable outer covering where it exits the nose of the grommet to ensure the following conditions:
^ Verify the cable exits the nose of the grommet at 90 degrees to the flange. (Figures 2)
^ Verify there are no white stress marks" on the outer cable. (Figure 3)
NOTE:
Cable "polishing" will cause one side of the cable to appear brighter when compared with the normal matt finish of the inner cable.
6. If no evidence of external throttle cable damaged is found, confirm internal cable wire condition as follows:
^ Slide the throttle cable outer cover towards the operating lever to expose 40 mm (1 1/2 inches) of inner cable at the bulkhead.
^ Carefully inspect the inner cable for evidence of polishing. (Figure 4)
^ Carefully inspect the inner cable for broken individual strands. (Figure 5)
7. If no evidence of internal or external cable damage is found, perform the following:
^ Install the cable at the throttle body end.
^ Go to "Adjust Installed Throttle Cable"
NOTE:
The cable O-ring/grommet will be reused on the replacement cable.
8. If the cable is polished, has broken strands, does not exit the grommet at 90 degrees to the flange or has evidence of a "white" stress mark at the grommet, perform the following:
^ Remove the damaged cable.
^ Transfer the O-ring/grommet from the original cable to the replacement cable.
^ Install the new cable following the procedure in the RAVE WSM section 19.20.06.
^ Go to "Adjust Installed Throttle Cable"
CAUTION:
The throttle cable adjustment procedure outlines in the RAVE WSM procedure sections 19.20.06 and 19.75.11 have been revised. The new procedure is contained in this bulletin.
ADJUST INSTALLED THROTTLE CABLE
1. Verify outer cable locknuts are loose.
2. Adjust the rear locknut to obtain a 0.5 mm (0.020in) gap, between the throttle cable lever and the throttle actuation plate. (Figure 6)
3. Tighten cable front locknut and verify that the required gap remains set.
4. If necessary adjust cruise control cable to obtain a 4 mm (0.160 in.) dimension between the throttle actuation plate and the cruise control lever.
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:
^ Recall code "D274"
^ 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.