Instruments - Intermittent Fuel Gauge Operation
No: 19/03/05/NASFGN 310-00
Ref:
Issue: 1
Date: 10 November 2005
Intermittent Fuel Gauge Operation
AFFECTED VEHICLE RANGE:
New Range Rover (LM) 3A101029 to 5A1980566
SITUATION:
SENDER UNIT FAILURE
A customer may report a concern that the fuel gauge is inoperative. The gauge may indicate that the fuel tank is empty even when it contains fuel. Investigation of the problem using T4 diagnostics reveals that the fuel gauge sender unit is the cause.
RESOLUTION:
REPLACEMENT SENDER UNIT TILE AVAILABLE FOR REPAIRS
Sender unit faults are now repairable with service parts that are now available. Replacement of the complete fuel pump assembly is no longer required to repair sender unit failures. Should a customer complain of inaccurate fuel gauge readings and T4 diagnostics indicate the sender unit, refer to the Repair Procedure detailed in this bulletin to replace both fuel level sender units.
PARTS INFORMATION:
DDW WARRANTY CLAIMS:
NOTE:
Repair procedures are under constant review, and therefore times are subject to change; those quoted here must be taken as guidance only. Always refer to DDW to obtain the latest repair time.
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
NOTE:
Fuel pump assemblies must not be changed for faulty sender problems.
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
DETERMINE FAULT WITH SENDER UNITS AND REPLACE
WARNING:
Always observer Workshop Manual precautions when working with fuel systems.
1. Using T4, establish that the fuel sender units are faulty.
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LM Range
Rover/2005 > Workshop Manuals > Range Rover
Workshop Manual Service Procedures > Bookmark
"19-2 Fuel Delivery System V8" > Link "19.45.03
Pump Fuel tank" 2. Refer to GTR Workshop Manual Section 19.45.03 and
remove the fuel pump and left-hand fuel sender units.
3. Release the sender unit electrical connector from the
side of the fuel pump and disconnect the connector.
(Figure 1)
4. Release the sender unit securing tang ("1" in Figure 1) and slide the sender unit from the fuel pump body. ("2" in Figure 1)
5. Install a new sender unit (WGO500010) to the fuel pump body.
6. Verify that the securing tang is positively engaged.
7. Connect the sender electrical connector and secure the connector to the fuel pump body.
8. Release the left-hand sensor assembly from the spring-loaded mounting and remove.
CAUTION:
It is critical to reconnect the lefthand sender unit pipes to the main fuel pump assembly fully. This can only be achieved from inside the tank, and should be practiced externally beforehand. When installed correctly, a positive "click" is heard.
NOTE:
Only the right-hand pipe joint on the main pump assembly has an O-ring installed. (Figure 2)
9. Replace the left-hand sender assembly with the new unit (WGI500010).
10. Refer to GTR Workshop Manual Section 19.45.03 and install the fuel pump and left-hand fuel sender units using new tank seal rings (WGQ500020).
11. Verify correct fuel gauge operation and reset adaptions as specified in GTR Workshop Manual.
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