Technical Service Bulletin

Transcription

1 group Climate Control Model Sedona (GQ) SUBJECT: NUMBER DATE 013 (Revised) May 2008 Technical Service Bulletin On some Sedona (GQ) vehicles built from May 1, 2001 to August 30, 2005, the heater coolant pipes may corrode and leak without warning. During scheduled maintenance, oil changes and/or other vehicle service, inspect the heater coolant pipes for severe corrosion. Corrosion is more likely in areas of the country that commonly spread corrosive compounds such as sodium chloride (salt) or calcium chloride on pavement to control freezing or melt ice and snow. Note too that during warm weather (or in warm climates) that calcium chloride may be used on some unpaved road surfaces to control dust. If any pipe or pipes are found to be severely corroded, replace the affected pipes with new ones, which are improved in corrosion resistance. File Under: Climate Control Circulate To: X General Manager X Service Manager X Parts Manager X Service Advisor(s) X Technician(s) X Body Shop Manager X Fleet Repair

2 Page 2 of 12 Service Procedure Front No. 1 Pipe Assembly Removal 1. Once the engine has cooled sufficiently, remove the radiator cap. Raise vehicle on lift. Cut the two flexible coolant hoses between the front coolant pipes and center coolant pipes as shown in the photo, and allow coolant to drain into a large container. A large amount of coolant will drain from these two hoses! 2. Remove the catalytic converter as shown. 3. Remove the splash shield from the sub-frame on the RH passenger side. TSB: Cli 013 Revised Sedona (GQ) May 2008

3 Page 3 of Remove the bolt holding the power steering lines on the RH passenger s side. 5. Detach the O2 sensor connector from the coolant pipes, then remove the (one) nut and (two) bolts that attach the coolant pipes to the body. 6. Lower the vehicle leaving the drain pan in place to catch any additional coolant. Remove the air filter assembly and intake hose to the throttle to access the area where the two heater hoses attach to the engine. The hose connections are below the thermostat / ECT area. See next photo. TSB: CLI 013 Revised Sedona (GQ) May 2008

4 Page 4 of Disconnect the two heater hoses from the engine as shown in the photo. Cut the two hoses just removed off of the original coolant pipe assembly as close to the coolant pipe connections as possible. This will aid in removing the coolant pipe assembly in the following steps. 8. Cut the coolant hoses off of the heater connections as close to the heater core as possible. Remove the clamps and remaining pieces of hoses from the heater core assembly. CAUTION Take extreme care not to damage the heater core or its connections! 9. Raise the vehicle on the lift. Loosen, but DO NOT remove completely, the two FRONT sub-frame nuts. Remove both rear sub-frame nuts and carefully pry the sub-frame down about 1 inch on the driver side, and about 1½ inches on the passenger side. Do NOT pry the driver side down further than recommended, as the steering rack is still attached, and may be damaged! TSB: Cli 013 Revised Sedona (GQ) May 2008

5 Page 5 of 12 It may be necessary to hold the sub-frame down on the RIGHT passenger side while removing the coolant pipe assembly. To accomplish this, you can place a shallow socket that is 1½ inch in height between the body and sub-frame assembly on the RH side, or some similar 1½ inch thick material. 10. Carefully remove the front coolant pipe assembly, noting its original positioning and routing for reference during reinstallation of the new part. Service Procedure Front No. 1 Pipe Assembly Installation 1. In preparation to installing the front coolant pipe assembly, turn both clamps for the heater hose connections 90 (¼ turn) outward as shown in the photo. Do NOT remove any hoses. This will allow the pipe to be positioned with greater ease. Install the front coolant pipe assembly. Start by inserting the hoses that connect to the engine first, and carefully work the remaining assembly up into place. 2. After the front coolant pipe assembly has been completely positioned, loosely reinstall the assembly to the body. Reattach all hose connections, and then fully tighten the coolant pipe assembly to the body. IMPORTANT: Check the clearance between the coolant pipes and hose connections, making certain that there is no contact between any other component, line / hose or electrical harness! TSB: CLI 013 Revised Sedona (GQ) May 2008

6 Page 6 of Install all remaining components in the reverse order of removal. If no additional coolant pipe assemblies will be replaced, proceed here with step 4. Otherwise, stop here and proceed with additional coolant pipe assembly replacement procedures. 4. Refill the system with coolant, referring to the table below for correct coolant mixture. Ambient Temperature Mixture Percentage (Volume) Coolant Water Solution -15 C (5 F) C (-13 F) C (-31 F) C (-49 F) After filling the system, the rear heater core / pipe assemblies can easily be bled of air by temporarily clamping off either FRONT heater core connection while raising the engine speed to approximately 2500 RPM for about one minute. 5. Carefully check for any coolant leaks, and that both the front and rear heater s operate correctly. Service Procedure Center No. 2 Pipe Assembly Removal 1. Once the engine has cooled sufficiently, remove the radiator cap. Raise vehicle on lift. Cut the two flexible coolant hoses between the rear and center coolant pipe assemblies as shown in the photo, and allow coolant to drain into a large container. A large amount of coolant will drain from these two hoses! TSB: Cli 013 Revised Sedona (GQ) May 2008

7 Page 7 of 12 IMPORTANT: Do NOT cut hoses between the front and center pipe assemblies! 2. Loosen and slide forward the two clamps attaching the center coolant pipe assembly to the front coolant pipe assembly, and then loosen the hose connections themselves. Do NOT damage the hoses between these two assemblies, as they will be reused. 3. Remove the bolts holding the coolant pipe assembly to the body, and then remove the original center coolant pipe assembly itself. Additionally remove the two remaining clamps from the front end of the rear coolant pipe assembly and the hoses that were previously cut off. It may be necessary to loosen the two bolts at the rear of the front catalyst before removing the center coolant pipe assembly. Service Procedure Center No. 2 Pipe Assembly Installation 1. Install the new center coolant pipe assembly to the body, and then install the hose connections to the front and rear of the assembly. If no additional coolant pipe assemblies will be replaced, proceed here with step 2. Otherwise, stop here and proceed with additional coolant pipe assembly replacement procedures. TSB: CLI 013 Revised Sedona (GQ) May 2008

8 Page 8 of Refill the system with coolant, referring to the table below for correct coolant mixture. Ambient Temperature Mixture Percentage (Volume) Coolant Water Solution -15 C (5 F) C (-13 F) C (-31 F) C (-49 F) After filling the system, the rear heater core / pipe assemblies can easily be bled of air by temporarily clamping off either FRONT heater core connection while raising the engine speed to approximately 2500 RPM for about one minute. 3. Carefully check for any coolant leaks, and that both the front and rear heater s operate correctly. Service Procedure Rear No. 3 Pipe Assembly Removal 1. Once the engine has cooled sufficiently, remove the radiator cap. Remove the spare tire assembly, and then raise the vehicle on the lift. TSB: Cli 013 Revised Sedona (GQ) May 2008

9 Page 9 of Remove the RH passenger side rear wheel mud flap and bracket to allow better access to the rear heater core connections. 3. Cut the two flexible coolant hoses between the rear heater core assembly and rear coolant pipes as shown in the photo, and allow coolant to drain into a large container. A large amount of coolant will drain from these two hoses! IMPORTANT: Do NOT cut hoses between the center and rear pipe assemblies! TSB: CLI 013 Revised Sedona (GQ) May 2008

10 Page 10 of Loosen and slide forward the two clamps attaching the rear coolant pipe assembly to the center coolant pipe assembly, and then loosen the hoses connections themselves. Do NOT damage the hoses between these two assemblies, as they will be reused. 5. Remove the nuts holding the coolant pipe assembly to the body, and then remove the original rear coolant pipe assembly itself. Also, CAREFULLY remove the remaining clamps and hose s that were cut-off of the rear heater core assembly. CAUTION Take extreme care not to damage the heater core or its connections! Service Procedure Rear No. 3 Pipe Assembly Installation 1. Install the new rear coolant pipe assembly to the body, and then install the hose connections to the center coolant pipe assembly and the rear heater core assembly. Reinstall the mud flap / bracket and spare tire. If no additional coolant pipe assemblies will be replaced, proceed here with step 2. Otherwise, stop here and proceed with another coolant pipe assembly replacement procedure. TSB: Cli 013 Revised Sedona (GQ) May 2008

11 Page 11 of Refill the system with coolant, referring to the table below for correct coolant mixture. Ambient Temperature Mixture Percentage (Volume) Coolant Water Solution -15 C (5 F) C (-13 F) C (-31 F) C (-49 F) After filling the system, the rear heater core / pipe assemblies can easily be bled of air by temporarily clamping off either FRONT heater core connection while raising the engine speed to approximately 2500 RPM for about one minute. 3. Carefully check for any coolant leaks, and that both the front and rear heater s operate correctly. AFFECTED PRODUCTION RANGE: All Sedona (GQ) built between May 1, 2001 and August 30, 2005 PartS Information: Part Name Part Number Previous New Pipe & Hose Assembly Heater No. 1 0K52Y B 0K52Y BFFF 0K52Y C 0K52Y CFFF Pipe & Hose Assembly Heater No. 2 0K N 0K NFFF 0K M 0K MFFF Pipe & Hose Assembly Heater No. 3 0K K 0K KFFF TSB: CLI 013 Revised Sedona (GQ) May 2008

12 Page 12 of 12 warranty coverage: basic (new vehicle limited warranty): Use only ONE Labor Op Code Do NOT combine Labor Op Codes. If more than one heater pipe assembly needs replacement, then replace ALL heater pipe assemblies at the same time and use Labor Op Code 61210F00. Claim Type Causal P/N Qty N Code C Code W 0K52Y C 0 N56 C05 W 0K N 0 N56 C05 W 0K K 0 N56 C05 W 0K52Y C 0 N56 C05 Repair Description Labor Op Code Front No. 1 Heater Pipe Replacement Center No. 2 Heater Pipe Replacement Rear No. 3 Heater Pipe Replacement Replace ALL Heater Pipes 61211F F00 Time Related Parts Qty 1.5hr 0.5hr 0K52Y BFFF 0K52Y CFFF 0K MFFF 0K NFFF 61213F00 0.7hr 0K KFFF F00 1.8hr 0K52Y BFFF 1 0K52Y CFFF 0K MFFF 1 0K NFFF 0K KFFF N56: Rust, Corrosion C05: Rusty, Corroded TSB: Cli 013 Revised Sedona (GQ) May 2008