Recall - Fuel Tank Replacement
NUMBER726
DATE
25 0ct 2006
MODEL
XJ
SECTION:
310
RECALL:
Fuel Tank Replacement
AFFECTED VEHICLE RANGE:
Jaguar XJ
VIN:
G49701 to H13485
Model Year:
2006 to 2007
CONDITION SUMMARY:
POTENTIAL FUEL LEAK FROM FUEL TANK SEALS
Situation:
An issue has been identified on certain 2006 and 2007 Model Year XJ vehicles in the VIN Range G49701 to Hi 3485 imported into the United States and Canada. It is possible that some fuel tanks were not made to specification. The out-of-specification condition may prevent the fuel delivery module (FDM), jet pump module (JPM) and/or cluster valve (CV) seals from adequately sealing. The malfunction indicator lamp (MIL) may illuminate and the vehicle may exhibit a fuel odor. Particularly after completely refueling, liquid fuel may leak onto 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 to be issued the week of October 29th. Refer to Service Administration Bulletin 7-38U5A or 7-38CAN "Safety Recall R726 - Fuel Tank Replacement" for additional information. Dealers are to remove the existing tank on affected vehicles and replace it with a new specification tank assembly as outlined in the Repair Procedure section of this bulletin.
PARTS:
NOTE:
Allocation of fuel tanks to dealers has commenced at a rate determined by dealer sales and the supply stream. The Quarantine VOR ordering process is no longer required. The recall part numbers will, however, not be available for "open ordering" until stocks have reached an adequate level to support demand. Refer to Bulletin 7-39NA5 "Recall R726 - Revised Technical Helpline Process".
C2C 35618.....Fuel Tank Assembly Qty 1 Supercharged Vehicles
C2C 34867.....Fuel Tank Assembly Qty 1 Naturally Aspirated Vehicles
NOTE:
Removed tanks must be safely disposed of following local regulations and established Jaguar 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:
Direct Dealer Warranty (DDW) Warranty claims should be submitted quoting the program code R726 together with the relevant option code from the table. This will result in payment of the stated time and, where applicable, parts/miscellaneous expense codes.
As option codes are used, there is no requirement for you to enter parts or SRO information; these are repeated here for information only.
NOTE:
The option that contains the drive in/drive out allowance may only be claimed when the vehicle has been brought back into the workshop for this action alone to be undertaken.
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
FUEL TANK REPLACEMENT PROCEDURE
WARNING:
Refer to GTR for Cautions and Warnings associated with the approved method for draining the fuel tank.
NOTE:
Global Technical Reference (GTR) lookup sequence is as follows:
GTR Home > NAS > Service Information/ X350 - XJ/2006 >
Workshop Manuals > Bookmark "Powertrain/Fuel System/
310-00 Fuel System General Information" Link "Fuel Tank
Draining - VIN Range G45704 >"
1. Refer to GTR Workshop Manual section 310-00 and drain the fuel from the tank.
NOTE:
Global Technical Reference (GTR) lookup sequence is as follows:
GTR Home> NAS > Service Information/ X350 - XJ12006 >
Workshop Manuals > Bookmark "Powertrain/Fuel System/
310-01 Fuel Tank and Lines" Link "Fuel Tank 4.2L/3.5L/3.0L"
NOTE:
Retain and re-use original installation fasteners when performing this workshop procedure.
2. Refer to GTR Workshop Manual, section: 310-01 and remove the gas tank retaining all fasteners and clamps for installation of the new tank.
3. Disconnect the fuel tank harness electrical connector from the fuel pump. (Figure. 1)
4. Remove the fuel tank harness retaining clip from the fuel pump flange. Save the clip for re-assembly (Figure 2)
5. Remove and discard the tape securing the fuel tank harness to the fuel tank. (Figure 3)
6. Remove the fuel tank harness from the fuel tank.
7. With assistance, disengage and remove the fuel tank from the fuel tank heat shield.
8. With assistance, assemble the fuel tank heat shield to the new fuel tank.
9. Install and align the fuel tank harness to the new fuel tank. (Figure 4)
10. Secure the fuel tank harness to the new fuel tank using duct tape.
11. Install and fully seat the fuel tank harness retaining clip to the fuel pump flange. (Figure 5)
12. Connect the fuel tank harness electrical connector to the fuel pump. (Figure 5)
13. Remove the tape securing the vent tube to the replacement tank for transportation.
14. Align the new vent tube to the fuel tank. (Figure 6)
CAUTION:
The vent tube must be fully seated into the retaining clips on the fuel tank to ensure proper retention.
15. Install the vent tube fully onto the retaining clips on the tank. (Arrowed in Figure 6)
16. Connect the vent tube onto the fuel pump flange connector. (Figure 7)
17. Refer to GTR Workshop Manual, section: 310-01 and install the new fuel tank into the vehicle.
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