Recall - Fuel Tank Repair/Replacement: Overview
NUMBERR176
V 4 NAS
MODEL
S-TYPE
DATE
20 Apr 2007
*NAS VERSION '4' CONTAINS ENHANCED INFORMATION REGARDING SEAL
INSTALLATION AND GO / NO-GO GAUGE MEASUREMENT METHODS.*
Updated information is shown by gray areas and asterisks.
SECTION: 310 FUEL SYSTEM
RECALL: Fuel Tank Repair or Replacement
AFFECTED VEHICLE RANGE:
Jaguar S-TYPE
VIN:
N05049 N52047
Model Year:
2005
CONDITION SUMMARY:
INSPECT FUEL TANK REPLACE SEALS OR INSTALL REVISED SPECIFICATION TANK
Situation:
A concern has been identified with the fuel tank installed on certain 2005 Model Year S-TYPE vehicles in the VIN Range N05049 - N52047 imported into the United States and Canada.
These vehicles are specified with the Low Emission Vehicle Stage II evaporative emissions system.
It is possible that some fuel tanks were not made to specification. This may prevent the fuel delivery module, jet pump module or cluster valve seals from adequately sealing. The vehicle may illuminate a malfunction indicator lamp (MIL), exhibit a fuel odor or, possibly after completely refueling, liquid fuel may be seen on the ground. Liquid fuel, in the presence of an ignition source, could result in a fire.
Action:
Sold vehicles will be subject to the standard customer recall notification which started during the week of February 5th. Refer to Service Administration Bulletin 7-47USA or 7-47CAN "Safety Recall R176 Fuel Tank Replacement" for additional information. Dealers are to remove the installed fuel tank on affected vehicles, inspect the tank and determine if seal replacement is possible. If repair is NOT possible, the original tank is to be replaced with a tank manufactured to the approved specification following standard Workshop Manual procedures.
PARTS:
NOTE:
Removed tanks must be safely disposed of following local regulations and established Jaguar policy. Your Aftersales Market Managers (AMM) have been provided with further details on disposal cost reimbursement procedures incurred because of local legislation or high volume. Contact your AMM for additional information.
TOOL ID NUMBERS
WARRANTY:
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.
Warranty claims should be submitted quoting Campaign Code R176 together with the relevant option code from the table. This will result in payment of the stated time and associated parts. As option codes are used, there is no requirement for you to enter parts or labor; they are repeated here for information only. The option that allows for the drive in/drive out allowance can only be claimed if the vehicle is brought back into the workshop for this action alone to be undertaken.
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
FUEL TANK REMOVAL AND DISASSEMBLY
NOTE:
Fasteners and clamps removed from the originally installed tank are to be reused for the installation of the replacement fuel tank.
NOTE:
Global Technical Reference (GTR) lookup sequence is as follows:
GTR Home > NAS > Service Information/ S-TYPE - 2005 > Workshop Manuals >
Bookmark "Powertrain/Fuel System 310-01 Fuel Tank and Lines" Link "Fuel Tank 4.2L/2.5L/3.0L (19.55.01)"
*CAUTION:
The fuel tank MUST be removed in order to perform the inspection and
the repair of the fuel tank.*
WARNING:
The Warnings and Cautions associated with fuel tank draining and
removal contained in Global Technical Reference (GTR) literature website must be observed to avoid the risk of personal injury or collateral damage to vehicle components.
1. Refer to GTR Workshop Manual 310-01, Section 19.55.01. Drain and remove the installed fuel tank.
2. Refer to GTR section 310-01 and remove the fuel pump module and the fuel transfer pump from the fuel tank
*NOTE:
Some vehicles will have been assembled with shear heads on the
clamps. If installed the shear head is easily pushed off to reveal the standard clamp hex head.*
3. Undo the control valve retaining clamp.
4. Release and remove the control valve clamp.
5. Release and remove the control valve from the tank.
6. If the seal remains attached to the modules, slide the old seals over components (or over the top of the Module Flange) and remove, being careful not to bend the fuel level sender arm. (Figure 1)
CAUTION:
Tools may NOT be used to pry the seal off of the fuel tank. Sharp tools such as screwdrivers and pry bars can cause damage to the sealing surface.
7. If the seals remain attached to fuel tank, peel the seal off the tank by hand and discard. (Figure 2)
*FUEL TANK GO / NO-GO GAUGE INSPECTION*
CAUTION:
Only light finger tip pressure should be required to insert the GO/NO GO gauge into the fuel pump tank opening on the "GO" side.
1 Place the large GO gauge (tool number 0-93-0025) into the fuel pump tank opening with the "GO" side down and measure the opening as follows:
^ Rotate the gauge through 360 degrees *with light finger pressure and check for binding. (Figure 3)*
^ If binding is felt on the gauge, go to bulletin section "Replacement Fuel Tank Installation" below and install a new fuel tank.
2. Remove the GO gauge from the fuel tank.
3. Turn the GO gauge (tool number 0-93-0025) over and insert the NO GO side of the gauge into the tank opening as follows:
*^ Place the side without the cut-out into the tank opening first. (Figure 4)
^ Center the gauge with thumb and finger without applying downward pressure.(Figure 4)
^ Ensure that the NO-GO tab under the cutout has not dropped into the tank opening. (Figure 5)*
*CAUTION:
At no time should pressure be applied to the NO-GO gauge during the measurement rotation. (Figure 6)
4. Carefully rotate the gauge through 360 degrees while viewing the cut-out in the tool to verify that the NO-GO gauge tab does not drop inside the opening in any orientation.
5. If the NO-GO gauge binds, but does not drop cleanly down into the tank opening during the rotation, lift the gauge free and continue the inspection rotation.
CAUTION:
If the NO-GO gauge drops into the tank opening of its own weight at any point during the inspection rotation, the opening does not meet specification.*
6. If the NO GO gauge drops of its own weight into the fuel pump opening at any time, go to bulletin section "Replacement Fuel Tank Installation" and install a new tank. (Figure 7)
CAUTION:
Only light finger tip pressure is required to insert the GO/NO GO gauge into the transfer pump tank opening on the "GO" side.
7. Place the large GO gauge (tool number 0-93-0025) into the transfer pump tank opening and measure the opening as follows:
^ Rotate the gauge through 360 degrees and check for binding *as outlined is Step 1 above.*
^ If binding is felt on the gauge, go to bulletin section "Replacement Fuel Tank Installation" below and install a new fuel tank.
8. Remove the gauge from the fuel tank.
9. Turn the GO gauge (tool number 0-93-0025) over.
10. *Insert the NO_GO gauge without applying downward pressure as outlined in Step 3 above* to measure the transfer pump opening as follows:
^ Rotate the gauge through 360 degrees while viewing the cut-out in the tool to check if the gauge will fit inside the opening *as outlined in Steps 4-5 above*.
^ If the NO GO gauge does drop into the transfer pump opening at any time, go to bulletin section "Replacement Fuel Tank Installation" and install a new tank.
CAUTION:
Only light finger tip pressure is required to insert the GO/NO GO gauge GO/NO GO gauge into the control valve tank opening on the "GO" side.
11. Place the small GO gauge (tool number 0-93-0026) into the control valve tank opening and measure the opening as follows:
^ Rotate the gauge through 360 degrees and check for binding *as outlined is Step 1 above.*
^ If binding is felt on the gauge, go to bulletin section "Replacement Fuel Tank Installation" below and install a new fuel tank.
12. Remove the GO gauge from the fuel tank.
13. Turn the GO gauge (tool number 0-93-0026) over.
14. *Insert the NO_GO gauge without applying downward pressure as outlined in Step 3 above* to measure the control valve opening as follows:
^ Rotate the gauge through 360 degrees while viewing the cut-out in the tool to check if the gauge will fit inside the opening *as outlined in Steps 4-5 above*.
^ If the NO GO gauge does drop into the control valve opening at any time, go to bulletin section "Replacement Fuel Tank Installation" and install a new tank.
*TANK OPENINGS - PERMISSIBLE MINOR IRREGULARITIES
NOTE:
Nicks, burrs and minor inner edge defects are permissible on the immediate edge of the fuel tank cut hole. The tank seals do not seal against the inner cut hole edge.
NOTE:
Some tanks may exhibit a slight deformation or "waviness" around the tank flange surface. This is acceptable. The clamping loads on the seal ring applied during module assembly will correct these irregularities.
The "smoke test" performed at the end of this procedure in Step 16 of section "Install New Seals to Inspected Tank" will eliminate any tank that may have a flange surface that will not seal properly.
1. Inspect fuel tank openings to confirm that only minor inner edge inconsistencies, that are acceptable for a proper sealing operation to be performed, are present. (Figures 8-10)*
*TANK OPENING INSPECTION FOR UNACCEPTABLE PHYSICAL DAMAGE*
CAUTION:
If damage is found in the following inspection, a new fuel tank must be installed.
1. Visually inspect all three fuel tank openings for gouges, tool marks or damage that may impair tank seal performance. (Figures 11-14)
2. *If unacceptable damage is found at any opening as shown in the illustrations*, go to bulletin section "Replacement Fuel Tank Installation" and install a new tank.
INSTALL NEW SEALS TO INSPECTED TANK
CAUTION:
Care must be taken to ensure the fuel level sender arm is not bent.
CAUTION:
Grease or other lubricants are not to be used when installing the seal to the module. The seal must be moved up the surface of the module diameter EVENLY.
1. Install and fully seat the new fuel pump module seal to the module. (Figure 15)
2. Install and fully seat the new transfer pump module seal to the module.
CAUTION:
Fuel pump assembly pipes must be correctly oriented during pump assembly to the tank. (Figure 15)
3. Orient fuel pump pipes as illustrated and install and fully seat the fuel pump and fuel pipes assembly. (Figure 15)
4. Install and fully seat the fuel pump module clamping ring.
5. Install and fully seat the fuel pump module retaining worm clamp.
CAUTION:
Hand tools are the only permissible tools for tightening the retaining clamps.
6. Install and fully tighten the fuel pump module retaining worm clamp until the head sheers off.
7. Install, but do not fully seat, the transfer pump module.
8. Connect the transfer pump module to transfer pump module fuel pipes.
9. Install and fully seat the transfer pump clamping ring.
10. Install and fully seat the transfer pump module retaining worm clamp.
CAUTION:
Hand tools are the only permissible tools for tightening the retaining clamps.
11. Install and fully tighten to the transfer pump module retaining worm clamp until the head sheers off.
12. Install and fully seat a new fuel tank control valve seal to the valve.
13. Install and fully seat the fuel tank control valve.
14. Install and fully seat the control valve retaining worm clamp.
CAUTION:
Hand tools are the only permissible tools for tightening the retaining
clamps.
15. Install and fully tighten the control valve retaining worm clamp until the head sheers off.
16. Perform a smoke test using Jaguar recommended equipment before installing the tank into vehicle.
17. If the fuel tank fails the smoke test, go to bulletin section "Replacement Fuel Tank Installation" and install a new tank.
18. If the fuel tank passes the smoke test, refer to GTR Workshop Manual 310-01, Section 19.55.01, and install the inspected and resealed fuel tank to the vehicle.
19. Replenish the resealed tank with removed fuel and check for leaks at all fittings and connections.
REPLACEMENT FUEL TANK INSTALLATION
1. If indicated in the procedure above, refer to GTR Workshop Manual 310-01, Section 19.55.01, and install a new replacement fuel tank.
NOTE:
Removed tanks must be safely disposed of following local regulations and established Jaguar policy.
2. Replenish the new tank with removed fuel and check for leaks at all fittings and connections.
Disclaimer