Campaign - Fuel Filler Cap/Neck Inspection/Replacement
No: SB14ORef:
Issue: 1
Date: 12/19/03
SERVICE ACTION Fuel Cap/Filler Neck Sealing
AFFECTED VEHICLE RANGE:
NOTE:
A limited number of vehicles in Retailer inventory are affected by this Action.
Editor's note: This campaign applies to specific VIN's. Contact your local dealer for additional coverage information.
Discovery Series II (LT) 3A767790 to 4A830188
Build Date 26 February 2002 to 13 August 2003
SITUATION:
POOR SEAL BETWEEN FILLER NECK AND FILLER CAP
NOTE:
The symptoms outlined for poor filler cap fit condition may also be indicative of a trickle valve failure.
Discovery vehicles in Retailer inventory before the safe VIN may have a fuel filler neck thread manufactured out of specification. This can cause the fuel filler cap to bind and prevent the cap from sealing adequately prior to the start of the fuel filler cap ratchet process. A fuel vapor leak from the filler cap area can cause the MIL lamp to illuminate and fault codes P0446 and P0455 may be logged.
RESOLUTION:
TEST AND IF INDICATED REPLACE FUEL CAP AND/OR FILLER NECK
NOTE:
This Service Action is for un-sold vehicles held in Retailer inventory only.
Prior to customer delivery test the seal integrity of the fuel filler cap on all vehicles in Retailer inventory before the above VIN. Where indicated, replace either the fuel cap or both the cap and filler neck. This Service Action covers both 2003 and 2004 model year inventory.
PARTS INFORMATION:
WLD500100 Fuel filler cap Qty 1
WMJ500140 Fuel filler neck Qty 1
LRN0002LABEL Campaign Label Qty 1 (NOTE: Sold in quantity pack of 100)
AS400 WARRANTY CLAIMS: (Canada Only)
NOTE:
Drive cycle not permitted for codes P0446 or P0445.
H140 (Option A) Time 0.40 hrs
Check fuel cap sealing integrity - Includes: TestBook/T4 "Sub System Test"
H140 (Option B) Time 0.50 hrs
Check fuel cap sealing integrity - Includes: drive in/out allowance,
TestBook/T4 "Sub System Test"
H140 (Option C) Time 0.60 hrs
Check fuel cap sealing integrity and replace cap - Includes: drive in/out allowance,
TestBook/T4 "Sub System Test"
H140 (Option D) Time 1.30 hrs
Check fuel cap sealing integrity and replace cap and filler neck - Includes:
drive in/out allowance, TestBook/T4 "Sub System Test"
DDW WARRANTY CLAIMS:
Warranty claims should be submitted quoting program code B140 together with the appropriate option code. This will result in payment of stated time and where applicable parts/miscellaneous expense.
The SRO information listed in the Table is for information only. There is no requirement to enter the SRO onto the claim.
NOTE:
Drive cycle not permitted for codes P0446 orP0445.
The options that allow for drive in/drive out may only be claimed when the vehicle has been brought into the workshop for this action alone to be undertaken.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
TEST FILLER CAP SEAL INTEGRITY
NOTE:
It is important to verify that the unsold vehicle is subject to this Service Action and has not had the repair performed at the Port of Entry.
1. Verify that the vehicle is subject to the Service Action.
2. Remove the fuel filler cap and verify that the sealing surface is in good condition and free of dirt.
3. Install the fuel filler cap and tighten until ratcheting begins and three "clicks" are heard/felt.
4. Connect TestBook/T4 to the vehicle and load disc "Archive 21" or a later version.
CAUTION:
TestBook/T4 may not be disconnected until the end of the procedure when instructed to do so.
5. Follow the on-screen instructions and select "Diagnostic System".
6. Clear any fault codes.
7. Follow the on-screen instructions and select "Petrol Engine".
8. Follow the on-screen instructions and select "Sub System Test".
9. Follow the on-screen instructions and select "Evaporative Leak" to carry out the Diagnostic Module Test Leakage (DMTL).
10. If an evaporative leak is detected, install a new fuel filler cap (WLD500100).
11. With TestBook/T4 still connected to the vehicle, perform a second DMTL test (steps 5 through 9).
12. If an evaporative leak is detected, refer to RAVE section 19.55.07 and install a new fuel filler neck (WMJ500140).
13. Install the new cap into the new filler neck.
14. With TestBook/T4 still connected to the vehicle, perform another DMTL test (steps 5 through 9).
NOTE:
Any evaporative leaks detected other than the fuel filler cap or fuel filler neck, are to be carried out as a separate Warranty Claim and are NOT part of this Service Action.
15. If an evaporative leak is detected, use service tool LRA-19-005A (Evaporative Emissions Tester), establish the cause of the evaporative leak and correct. File a separate claim.
16. Disconnect TestBook/T4 from the vehicle.
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:
^ Service Campaign code "B140"
^ 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.
4. Roll the label with the special roller tool to ensure proper adhesion.