Recall P001/RB016 - Fuel Tank Replacement
SECTION: 310-01BRECALL: Fuel Tank Replacement
AFFECTED VEHICLE RANGE:
Land Rover LR3 (LA) VIN: 5A000360 to 5A342827 - Specific Vehicles
5A342834 to 6A359153
CONDITION SUMMARY:
DISCONNECTED VAPOR RECOVERY SYSTEM TUBE POSES RISK FOR FUEL LEAK
NOTE:
This Recall is an extension of the Recall B016 VIN range into the 2006 Model Year. It also includes a relatively small number of repaired vehicles in the B016 vehicle population (5A000360 to 5A342827) that will require a new tank. The affected vehicles were built or repaired with an "interim" tank configuration that now requires replacement. The new Recall number has been utilized to clearly track and identify all vehicles involved in this expansion of the original B016 Recall. The P001 repair procedure is the same as the previously issued Recall B016.
Situation: Land Rover has decided to recall vehicles in the affected VIN ranges to install a replacement fuel tank. Under certain circumstances a fuel tank internal breather tube can become disconnected. When the fuel level in the tank is above the level of the detached joint, fuel may then enter the breather tube. The vehicle may exhibit Check Engine (MIL) symbol illumination, fuel odor, and drivability concerns such as hesitation, misfire, stalling, rough running or difficulty in starting. If the amount of fuel flowing into the breather tube reaches the vapor canister and exceeds its capacity, the excess fuel may be discharged onto the ground. Liquid fuel, in the presence of an ignition source could result in a fire.
Action: Under the provisions of this Recall action the fuel tank assembly will be replaced.
PARTS:
WHK500220.............Fuel Tank Qty 1
NOTE:
Removed tanks must be safely disposed of following local regulations and established Land Rover policy. Your Aftersales Market Managers (AMM) has been provided with further details on disposal cost reimbursement procedures incurred because of local legislation or high volume. Contact your AMM for additional information.
WARRANTY
Warranty claims should be submitted quoting program code P001 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.
NOTE:
Removed tanks must be safely disposed of following local regulations and established Land Rover policy. Your Aftersales Market Managers (AMM) has been provided with further details on disposal cost reimbursement procedures incurred because of local legislation or high volume. Contact your AMM for additional information.
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.
REPAIR PROCEDURE
REMOVE FUEL TANK
NOTE:
GTR lookup sequence is as follows:
GTR Home> NAS > Service Information/LA LR3/2005 > Workshop Manuals> Discovery 3 / LR3 2005 Workshop Manual > Open Bookmarks "Powertrain/Fuel System/310-01B: Fuel Tank and Lines - 4.4L"> Link "Fuel Tank (19.55.01)"
WARNING:
Always observe Workshop Manual procedures, Warning and Cautions when working with gasoline systems on the vehicle.
^ The vehicle must be placed in a well-ventilated, quarantined area. "No Smoking/Gasoline Fumes" signs should be displayed about the vehicle.
^ Cellular phones pose the risk of person injury when used in the vicinity of any fuel related components. Highly flammable vapors are always present and may ignite.
^ Smoking or carrying lighted tobacco or open flame of any type when working on or near any fuel related components could result in personal injury. Highly flammable vapors are always present and may ignite.
^ The spilling of fuel is unavoidable during this operation. All necessary precautions must be taken to prevent fire and explosion.
^ Before disconnecting or removing components, the area around the joint faces and connections must be clean. Open connections must be plugged to prevent contamination.
1. Disconnect the battery ground cable.
2. Drain the fuel tank contents into a clean fuel caddy for future refill.
WARNING:
Always support the vehicle on safety stands when working under it.
3. Raise and support the vehicle.
4. Remove the three bolts and two nuts securing the fuel tank heat shield (Figure 1).
CAUTION:
Before the disconnection or removal of any components, the area around joint faces and connections must be clean. Open connections should always be plugged to prevent contamination.
5. Disconnect the fuel filler neck from the filler neck hose:
^ Remove the tamper-proof clamp screw cover if fitted.
^ Remove the hose clamp from the filler connector hose. (Figure 2)
6. Disconnect the fuel supply and purge lines quick release connections at the front of the fuel tank. (Figure 3)
7. Disconnect the fuel tank vent line at the rear of the fuel tank, over the integrated body frame. (Figure 4)
8. Release the fuel tank harness.
9. Release the parking brake emergency release cable and the two emergency release cable clips. (Figure 5)
WARNING:
To ensure stability the fuel tank must be secured to the transmission jack.
NOTE:
The rear bolt is fitted with 2 washers.
10. Secure the tank to a suitable transmission jack and remove the six fuel tank retaining bolts. (Figure 6)
CAUTION:
Connectors at the top of the tank permit lowering the fuel tank only 250 mm (9.75 in) in the following step.
11. Lower the fuel tank sufficiently to access the top of the fuel tank - approximately 9 inches.
12. Disconnect the fuel pump module electrical connector. (Figure 7)
13. Release the purge line from the top of the fuel tank (Figure 8):
^ Remove the adhesive pad.
^ Release from the five clips.
14. Lower the fuel tank.
CAUTION:
Before the disconnection or removal of any components, ensure the area around joint faces and connections are clean. Plug any open connections to prevent contamination.
15. Remove the fuel tank vent line (Figure 9):
^ Disconnect the quick release connector.
^ Remove from the 3 clips.
16. With assistance, remove the fuel tank from the transmission jack.
17. Remove the fuel tank bracket (Figure 10):
^ Remove the two clips.
^ Remove the two bolts.
^ Remove the retaining plate.
INSTALL NEW FUEL TANK WHK500220
1. Install the fuel tank bracket on the new tank assembly:
^ Install the retaining plate.
^ Install the clips.
^ Tighten the bolts to 3.5 Nm (2.5 lbf-ft).
2. With assistance, position and secure the replacement fuel tank assembly onto the transmission lack.
3. Position the fuel tank under the vehicle, allowing access to the top of the tank.
4. Secure the purge line to the fuel tank:
^ Secure with the clips.
^ Install the adhesive pad.
5. Connect the electrical connector.
NOTE:
The rear bolt is fitted with 2 washers
6. Install the fuel tank and tighten the bolts to 45 Nm (33 lbf-ft).
7. Install the two emergency release cable clips.
8. Secure the parking brake emergency release cable and secure the four securing clips.
9. Secure the fuel tank electrical harness.
10. Install the vent line as follows:
^ Connect the quick release connector.
^ Secure into the 3 clips
11. Connect the fuel supply and purge lines.
12. Connect the fuel filler neck as follows:
^ Position the removed retaining hose clamp over the tank hose.
^ Install the hose over the filler pipe.
^ Tighten the hose clamp to 3-4 Nm (2-3 lbf-ft).
13. Install the fuel tank heat shield as follows:
^ Position the shield to the tank.
^ Tighten the bolts to 5 Nm (4 lbf-ft).
^ Tighten the nuts to 3 Nm (2 lbf-ft).
14. Refill the fuel tank with removed gasoline.
15. Check for security of fuel, purge and vent lines.
16. Connect battery ground cable.
17. Start and run the engine for a minimum of two minutes.
Disclaimer