Coolant Leak Discovery Series II - Defender Source
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  #1  
Old January 20th, 2010, 08:22 PM
aosias's Avatar
aosias
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Alexandra
1995 D90
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Location: Boulder, CO
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Coolant Leak Discovery Series II

I have a 2003 Disco II with 60k miles on it. It's due for the 60k service and an oil change.

When I was getting fuel yesterday I checked the oil and noticed an orange gel over my head cover on the left side under the TBI. Checked the coolant and it was at about half. I noticed a funky smell about a week ago but it hasn't been consistent. No new stains on the driveway, no change in performance or increase in temp.

Coolant has covered the top of the head and appears to be coming out of the TBI. Where should I start to address this problem? Is this a sign of a much larger issue?


Thanks,
Alex
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  #2  
Old January 20th, 2010, 08:37 PM
rmuller
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Ryan
1966 S2a 88" | 2006 LR3
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Location: Caldwell, NJ
Posts: 1,056
You're lucky...very common coolant leak on a D2.. the throttle body pre-heater plate gasket goes out... fast easy fix... buy a new kit;

http://www.roverparts.com/Parts/MGM000010KG.cfm

switch out the gasket and the plate and you should be fine.

------ Follow up post added January 20th, 2010 08:38 PM ------

Here's the TSB too;

Quote:
SERVICE ACTION

Throttle Body Heater Gasket Replacement

AFFECTED VEHICLE RANGE:

DISCOVERY SERIES II (LT) XA200412 to XA208015
XA900000 to XA904569

SITUATION:

DURABILITY IMPROVEMENTS TO THROTTLE BODY HEATER GASKET

A change in material used for the throttle body heater gasket improves the service life of the component.

RESOLUTION:

REPLACE GASKET WITH NEW SPECIFICATION GASKET

Under this Service Action the new-specification throttle body heater gasket will be installed to improve the reliability of the vehicles within the specified VIN range.

PARTS INFORMATION:

NOTE: Early specification spare parts held in retailer inventory may be returned using the PAF claim process. Use reason code OH and reference this TIB on the claim.

MGM000010K Throttle body plate kit Qty 1
ERR6623 Throttle body gasketQty 1

ITEMS INCLUDED IN THE MATERIAL ALLOWANCE:

^ (Locally Sourced)Liquid gasket remover As Required

^ LRN0002LABEL Campaign label Qty 1 (Order quantity 1 = 100)

WARRANTY CLAIMS:

H230 (Option 1) Time 1.00 hrs.
Perform gasket replacement
Material Allowance: $2.00

H230 (Option 2) Time 0.20 hrs
Inspect throttle body and determine that Service Action is not required

NOTE: In order to determine if a specific vehicle is affected by this Service Action, it will be necessary to utilize the Vehicle Warranty/Recall Search function of the DCS - Land Rover Link On-line. Based on the response of the system, either proceed with the corrective action or take no further action.

Normal warranty policy and procedures apply

REPLACEMENT OF THROTTLE BODY HEATER GASKET

INSPECT TO DETERMINE THROTTLE BODY PART NUMBER

1. Locate the part number tag on the throttle body.

2. If the part number on the label is not "MHB101890", go to "Campaign Label Installation" and perform label installation to identify that the vehicle has been inspected. Claim Option 2.

3. If the part number on the label is "MHB101890," complete the repair.


SERVICE ACTION REPAIR

1. If the part number tag reads "MHB101890," remove the throttle body following Workshop Manual procedure in Section 19.22.45.

2. Disassemble throttle body as follows:

^ Remove the three water jacket screws.

^ Remove the water jacket cover.

^ Discard the cover, screws, washers and gasket.

CAUTION: Metallic tools or abrasive material can cause damage to the gasket surfaces. Only liquid gasket remover should be used.

3. Remove the remains of the old gasket from the throttle body using care not to damage the housing.

4. Ensure the throttle body water jacket cover mating face is thoroughly clean.








5. Install the gasket, cover and screws supplied in kit MGM000010K. (Figure 1)

6. Tighten the screws to 4.0 - 4.5 Nm (35.4 - 39.8 lbf.in.).

7. Apply the new identification label to the throttle body.

8. Verify that the mating faces of the throttle body and inlet manifold are clean and all gasket material is removed.

9. Refer to Workshop Manual Section 19.22.45 and install the throttle body using a new gasket (ERR6623).

10. Install coolant hoses using clamps previously removed.

WARNING: Spilled fluids can be a hazard. Ensure that any fluids spilled during repairs in the under-hood area are cleaned up.

11. Top up the coolant system.

12. Road test the vehicle and verify no leaks are present.


CAMPAIGN LABEL INSTALLATION

NOTE: Campaign labels may have multiple campaign numbers written on them if multiple campaigns are performed at the same time.
__________________
Ryan
-------------
Current:
1966 Series IIa "Olive"
2001 Discovery II
2006 LR3 HSE7


Past: 1994 Defender 90 #416, 2001 Discovery II
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  #3  
Old January 20th, 2010, 09:27 PM
aosias's Avatar
aosias
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Alexandra
1995 D90
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Join Date: Feb 2006
Location: Boulder, CO
Posts: 1,348
Registry
Thank you! Seems simple enough. BTW how do I clean the orange goo from the head cover?
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  #4  
Old January 25th, 2010, 12:04 PM
rmuller
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Ryan
1966 S2a 88" | 2006 LR3
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Join Date: Nov 2004
Location: Caldwell, NJ
Posts: 1,056
I just usually wipe it off... use some brake cleaner or gunk or something.
__________________
Ryan
-------------
Current:
1966 Series IIa "Olive"
2001 Discovery II
2006 LR3 HSE7


Past: 1994 Defender 90 #416, 2001 Discovery II
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