Recall - Fuel Tank Replacement (Canadian Vehicles): Overview
No: RB156C (Canada)FGN
Ref: SA04RE-02
SAO4RE-09C
SB173
*Issue: 3
Date: June 2005*
Update information is noted by asterisks and shaded areas.
RECALL
Fuel Tank Replacement
AFFECTED VEHICLE RANGE:
Range Rover Classic (LH) PA637653 to SA662245
Discovery Series I (LJ) SA079287 to TA199999
TA500000 to VA546039
VA700000 to VA714242
SITUATION:
FUEL ODOR AFTER FILLING FUEL TANK
A concern has been identified with the fuel tanks on vehicles within the above VIN ranges. Under certain circumstances the fuel tank weld joint for the vent rings could crack permitting leakage. Liquid fuel, in the presence of an ignition source could result in a fire.
RESOLUTION:
REPLACE FUEL TANKS ON AFFECTED VEHICLES
NOTE:
Two previous Alerts and Service Action SB173 have announced interim procedures to be used when dealing with customer complaints relating to fuel odors in vehicles affected by Recall B156 until replacement gas tanks are routinely available.
^ Service Alert SA04RE-02 announced a process for dealing with fuel odor complaints and informed Retailers to contact the Technical HelpLine.
^ Service Alert SA04RE-09C informed Canadian Retailers of an action plan to notify Canadian customers about the potential for a fuel odor condition in their vehicles. If a customer presents one of these letters with a complaint of fuel odor, the Service Action B173 inspection and resolution procedure should be used.
^ Service Action SB173 announced the repair and claim procedure to perform this Recall upon customer complaint of a fuel odor or leak.
This edition of the Recall bulletin supersedes all of the above bulletins and the previously published RB156 Issue 2. Issue 3 also provides enhances workshop procedure instructions to clarify the previously referenced GTR material. Follow the procedure for Discovery (LJ) or Range Rover Classic (LH) outlined in this bulletin to make the repair.
This Recall action is being undertaken to replace fuel tanks in all affected vehicles following standard Workshop Manual procedures.
PARTS INFORMATION:
DDW WARRANTY CLAIMS:
Warranty claims should be submiffed quoting program code B156 together with the appropriate option code. As option codes are used, there is no requirement to enter parts or labor. They are provided for information only.
Drive in/drive out can only be claimed if the vehicle is brought back into the workshop for this action alone to be undertaken.
Warranty claims should be submitted in accordance with the current Land Rover Warranty Policy and Procedures Manual and its amendments unless stated otherwise in this Recall Action.
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
REPLACE FUEL TANK
WARNING:
All precautions relating to fuel handling established in the Workshop Manuals must be carefully observed.
*NOTE:
The GTR procedures previously referenced in Edition 1 and Edition 2 of this bulletin do not provide the most complete instructions for this Recall. The following procedures should be used for the affected vehicle type to ensure the most efficient and effective repair process.
ALL of the "Repair Procedure" section of this bulletin contains new material. No change shading is applied to the work methods specified in this section.
The original process for the fuel tank removal and installation processes on Discovery and Range Rover Classic models has been clarified using additional text and illustrations. Some steps have been removed (for example use of TestBook/T4) and others, including the fuel drain, were optimized for more effective fuel recovery and refill using a fuel recovery system with a 12 mm bore extraction hose.
Warranty times have been re-calculated using the latest tools and equipment on aged and high mileage vehicles. In this re-calculation, additional labor allowances have been made for removal of some fasteners that may be subject to corrosion. Overall, the study has led to a reduction in the repair procedure time compared with the time published prior to this Recall.
The relevant Workshop Manual Sections that these procedures relate to will be updated on GTR at the next available opportunity.