Recall - Fuel Filler Neck Modification
No: D217Ref: 19/02/98/NAS
Issue: 1
Date: 07/14/00
RECALL
Fuel Filler Cap Closure
AFFECTED VEHICLE RANGE:
Discovery (U) VA714288 to XA799996
Discovery (U) VA546050 to XA567232
Discovery (U) XA400001 to XA400549
SITUATION:
POOR SEAL BETWEEN FILLER NECK AND FILLER CAP
The customer may experience a MIL illumination as the result of an insufficiently tight fuel filler cap. This condition can be caused by body panel tolerance variation between the fuel filler quarter panel pocket and the lower mounting location for the filler neck. The sealing surface of the filler neck can drop below the top surface of the mounting grommet. This condition results in a poor seal between the filler cap and filler neck.
RESOLUTION:
NOTE:
This Recall TIB replaces TIB 19/02/98/NAS. The Recall repair should also be performed whenever an incomplete seal of the filler cap causes a P1496 fault code.
INSTALLATION OF SPACER RING
All vehicles within the affected VIN range are to have a split spacer ring installed below the lip of the filler neck. This will prevent the filler neck from dropping below the surface of the grommet and thus eliminate the risk of an incomplete seal between the filler cap and filler neck.
PARTS INFORMATION:
WL0000010 Split ring Qty 1
LRN0002LABEL Campaign Label Qty 1 (Order quantity 1 pack of 100)
LRN0003CAEM CA P of C Form Qty 1 California Only (Order qty 1 pad of 50)
WARRANTY CLAIMS:
D217 Time 0.30 hrs.
Install split ring on filler neck
Material Allowance is incorporated into the time allowance for repair
NOTE:
In order to determine if a specific vehicle is affected by this campaign, it will be necessary to utilize the Vehicle Warranty/Recall Search function of the Land Rover Link online DCS. Based on the response of the system, either proceed with the corrective action or take no further action.
Normal warranty policy and procedures apply
REPAIR PROCEDURE
WARNING:
Automotive fuel vapors are flammable. Section 03 Workshop Manual fuel handling precautions and all local regulations must be observed.
1. Remove the fuel filler cap.
2. Release the screw that attaches the filler neck to the mud flap bracket behind the rear fender.
3. Insert a finger into the filler neck and through the flap opening.
4. Lift the filler neck as far as it will easily go - approximately 10-15mm (0.4 - 0.6 inch).
5. Open up the split ring (WLO000010) and position it over the top of the filler neck. (Figure 1)
6. Slide the split ring down flush with the top of the grommet.
CAUTION:
The split ring must be positioned below the grommet top surface in the next step.
7. Starting from one end of the split ring and working in a counter clockwise direction, push the ring under the grommet lip. (Figure 2)
8. Release the filler neck and then gently push it downward until the lip of the filler neck rests on the split ring. (Figure 3)
9. Install the filler neck fastener to the mud flap bracket.
10. Install the fuel filler cap.
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 Campaign code "D217"
^ 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.