7-047USA3

Safety Recall R176 (NHTSA # 06V-418): Fuel
SERVICE
Tank Replacement
18-AUG-14
No.:
BULLETIN
7-047USA
(Issue 3)
Section:
RECALL
Market:
USA
CHANGES ARE NOT HIGHLIGHTED
Jaguar Land Rover North America, LLC has informed the National Highway Transportation Safety
Administration (NHTSA) of its intent to perform a Safety Recall on 2005 model year Jaguar S-TYPE
vehicles imported into the United States market. Information relating to the proposed Recall will be
posted on the NHTSA website.
United States Federal regulations require that retailers must be advised of this Recall notification within
three working days after government notification.
United States Federal law requires retailers to complete any outstanding safety Recall service before a
new vehicle is delivered to the buyer or lessee. Violation of this requirement by a retailer could result in a
civil penalty of up to $7,000.00 per vehicle.
This Recall Service Bulletin serves as notification to all Jaguar retailers in the United States and Puerto
Rico that any affected new vehicles may not be sold and delivered for customer use until the Recall repair
is completed.
DESCRIPTION
Jaguar has identified a concern with fuel tanks fitted to 2005MY Jaguar S-TYPE vehicles. Some of the affected
vehicles may have fuel tanks in which the fuel delivery module (FDM), jet pump module (JPM), and/or cluster
valve (CV) seals are not properly retained in the fuel tank. This may result in illumination of the malfunction
indicator lamp (MIL), or a fuel odor. If the fuel level is above the FDM, JPM, or CV apertures, fuel may be
discharged onto the ground. Leaks are most likely to occur only after a fuel tank has been fully filled.
Liquid fuel, in the presence of an ignition source, could result in a fire.
AFFECTED VEHICLES / OWNER NOTIFICATION
The VIN range of affected vehicles is N05049-N52047.
Owner notification began the week of 5 February 2007.
WORKSHOP PROCEDURES
Retailers are required to check DDW to ensure that the vehicle is affected by this program prior to undertaking
any rework action. Retailers are required to HOLD all affected vehicles in the above VIN range that are in their
control and refrain from releasing the vehicles for new or used vehicle sale pending completion of the rework
action. Affected vehicles already in the hands of customers should be updated at the next available opportunity.
Refer to Technical Bulletin R176NAS: Safety Recall: Fuel Tank Replacement, for detailed repair instructions.
Jaguar Land Rover North America, LLC
555 MacArthur Boulevard
Mahwah, NJ 07430
PARTS
TABLE 1 – 4.2L V8 SUPERCHARGED VEHICLES ONLY
DESCRIPTION
PART NO. / SUNDRY CODE
QTY. /
VALUE
C2Z29212
Fuel tank
1
C2D25079
Fuel pump
1
C2D25076
Flange
1
C2Z7361
Gasket
1
C2Z7352
Retaining ring
1
C2Z8500
Pipe - fuel feed
1
C2Z21711
Strap - tank left-hand
1
C2Z21684
Strap - tank right-hand
1
C2Z10210
Heatshield
1
C2Z4771
Hose - fuel filler
1
XR858662
Heat-sleeve
1
XR858628
Evaporator pipe
1
XR858660
Fuel pump module
1
XR858670
Fuel tank harness
1
AAU5884J
Cable tie - 50mm (L) X 2mm (W)
8
C2C8870
M6 nut with flange
2
C2D13865
M5 nut with flange
2
XR858671
Cabin overlay wiring harness
1
Other
Suitable tape (locally sourced)
RTV silicon sealant (locally sourced)
Four (4) 150mm-length cable ties (locally sourced)
*$5.00
NOTE: An allowance of $5.00 has been allocated to cover the cost of locally sourced duct tape, silicon
sealant, and 150mm-long cable ties.
Displaced tanks MUST be rendered unusable and safely disposed of in accordance with local policies and
procedures. For recovery of disposal costs, please refer to the Related Damage section within the Warranty
information.
TABLE 2 – 3.0L V6 / 4.2L V8 NATURALLY ASPIRATED VEHICLES ONLY
DESCRIPTION
PART NO. / SUNDRY CODE
QTY. /
VALUE
C2Z29213
Fuel tank
1
C2Z23192
Fuel pump
1
C2D25076
Flange
1
C2Z7361
Gasket
1
C2Z7352
Retaining ring
1
C2Z8500
Pipe - fuel feed
1
C2Z21711
Strap - tank left-hand
1
C2Z21684
Strap - tank right-hand
1
C2Z10210
Heatshield
1
C2Z4771
Hose - fuel filler
1
XR858662
Heat-sleeve
1
XR858628
Evaporator pipe
1
XR858626
Fuel tank wiring harness
1
AAU5884J
Cable tie - 50mm (L) X 2mm (W)
8
XR857854
M6 nut with flange (ground wire fixing)
1
XR858627
Ground lead
1
-
Suitable tape (locally sourced)
*
XR858630
Instrument Cluster
1
XR858629
Resistor box
1
-
RTV silicon sealant (locally sourced)
Four (4) 150mm-length cable ties (locally sourced)
*$5.00
NOTE: An allowance of $5.00 has been allocated to cover the cost of locally sourced duct tape, silicon
sealant, and 150mm-long cable ties.
Displaced tanks MUST be rendered unusable and safely disposed of in accordance with local policies and
procedures. For recovery of disposal costs, please refer to the Related Damage section within the Warranty
information.
TOOLS
Refer to Service Instruction / Workshop Manual for any required tools
WARRANTY
NOTE: Check DDW to ensure that the vehicle is affected by this program prior to undertaking any rework
action. Repair procedures are under constant review, and therefore times / prices are subject to change; those
quoted here must be taken as guidance only. Refer to TOPIx to obtain the latest repair time. At the time of
confirming a booking for vehicle repair, ensure that all outstanding Service Actions are identified to ensure the
correct parts are available and adequate workshop time is allocated for repairs to be completed at one visit.
Warranty claims must be submitted quoting Program Code 'R176' together with the relevant Option Code from the
table. SRO and parts information is included for information only. The Option Code(s) that allows for the drive in /
drive out allowance can only be claimed if the vehicle is brought into the workshop for this action alone to be
undertaken.
Warranty claims must be submitted for payment within 30 calendar days of completion of the repair.
PROGRAM
CODE
R176
R176
R176
OPTION
CODE
DESCRIPTION
SRO
TIME
(HOURS)
QTY. /
VALUE
NOTE: 4.2L V8 Supercharged vehicles only
Fuel tank service fix
19.92.08
5.0
C2Z29212
C2D25079
C2D25076
C2Z7361
C2Z7352
C2Z8500
C2Z21711
C2Z21864
C2Z10210
C2Z4771
XR858662
XR858628
XR858660
XR858670
AAU5884J
C2C8870
C2D13865
XR858671
Other
1
1
1
1
1
1
1
1
1
1
1
1
1
1
8
2
2
1
$5.00
NOTE: 4.2L V8 Supercharged vehicles only
Fuel tank service fix
19.92.08
5.0
Drive in/drive out
10.10.10
0.1
C2Z29212
C2D25079
C2D25076
C2Z7361
C2Z7352
C2Z8500
C2Z21711
C2Z21864
C2Z10210
C2Z4771
XR858662
XR858628
XR858660
XR858670
AAU5884J
C2C8870
C2D13865
XR858671
Other
-
1
1
1
1
1
1
1
1
1
1
1
1
1
1
8
2
2
1
$5.00
-
NOTE: 3.0L V6 / 4.2L V8 naturally aspirated
vehicles only
Fuel tank service fix
19.92.08
5.3
C2Z29213
C2Z23192
C2D25076
C2Z7361
C2Z7352
C2Z8500
C2Z21711
C2Z21864
C2Z10210
1
1
1
1
1
1
1
1
1
U
V
W
PART NO. /
SUNDRY CODE
R176
NOTE: 3.0L V6 / 4.2L V8 naturally aspirated
vehicles only
Fuel tank service fix
19.92.08
5.3
Drive in/drive out
10.10.10
0.1
Y
C2Z4771
XR858662
XR858628
XR858626
AAU5884J
XR857854
XR858627
XR858630
XR858629
Other
1
1
1
1
8
1
1
1
1
$5.00
C2Z29213
C2Z23192
C2D25076
C2Z7361
C2Z7352
C2Z8500
C2Z21711
C2Z21864
C2Z10210
C2Z4771
XR858662
XR858628
XR858626
AAU5884J
XR857854
XR858627
XR858630
XR858629
Other
-
1
1
1
1
1
1
1
1
1
1
1
1
1
8
1
1
1
1
$5.00
-
Normal Warranty policies and procedures apply
RELATED DAMAGES:
Supplementary claims for fuel tank disposal costs can only be made once the Recall claim has been accepted for
payment. Claims should be submitted quoting Program Code 'R176' and by clicking the 'Related Damage' radio
button on the claim submission screen. Use Option Code 'X', enter the disposal costs against Sundry Code
'Other', and quote the value in local currency.
PROGRAM
CODE
OPTION
CODE
R176
X
DESCRIPTION
Reimbursement of fuel tank disposal
SRO
-
TIME
(HOURS)
-
PART NO. /
SUNDRY CODE
Other
Displaced tanks MUST be rendered unusable and safely disposed of in accordance with local policies and
procedures.
QTY. /
VALUE
Dealer
entered
value
Safety Recall R176: Sample Owner Letter
RE: Safety Recall Action R176 - Fuel tank replacement
Vehicles Affected: Jaguar S-TYPE
Model Year: 2005
e
Dear Jaguar Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle
Safety Act. Jaguar Cars has decided that a defect, relating to motor vehicle safety, exists in certain 2005
model year S-TYPE vehicles. Investigations have determined that some of the fuel tanks in these vehicles
have seals that are not properly retained in the fuel tank. Your vehicle is included in this recall action.
m
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What is the concern?
Some of the affected vehicles may contain fuel delivery module (FDM), jet pump module (JPM) and/or
cluster valve seals located on the top of the tank that are not properly retained due to fuel tank manufacturing
variability and/or excessive clamp loads. If the sealing is inadequate, the On Board Diagnostic leak detection
system may sense an evaporative system hole of greater than 0.5 mm diameter and illuminate an amber
Malfunction Indicator Lamp on the instrument cluster (Check Engine Light). If the fuel tank is fully filled with
fuel or the vehicle is parked on a hill with a leak path present, the driver may notice fuel odor or fuel leakage.
A fuel leak in the presence of an ignition source may result in a fire.
What will Jaguar and your Jaguar dealer do?
Jaguar Cars is carrying out a voluntary recall of affected vehicles. An authorized Jaguar dealer will inspect
your fuel tank to determine if a repair using revised seals is possible. If the repair is not possible as indicated
by the inspection the dealer will replace your vehicle's fuel tank with a fuel tank that is manufactured to the
correct specification. All repairs will be performed free of charge.
What should you do?
Please contact your authorized Jaguar dealer at your earliest convenience to schedule an appointment to
have Safety Recall Action R176 completed on your vehicle. In the time prior to the Recall repair Jaguar
recommends, as a precaution, that your fuel tank be filled no more than 3/4 full. This precaution will reduce
the likelihood of leakage due to fuel contact with a defective seal.
How long will it take?
Expected repair time is estimated to be approximately three hours to install a new fuel tank. However, due to
service scheduling requirements at the dealer, your vehicle may be needed for a longer period of time.
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Attention Leasing Agencies:
Federal regulations require that you forward this recall notification to the lessee within TEN days.
Moved or no longer own a Jaguar?
If you are no longer the owner of this vehicle, Jaguar would greatly appreciate the name and address of the
new owner, using the enclosed return postage-paid card.
What should you do if you have further questions?
Should you have any questions regarding this Recall Action or need assistance in locating your nearest
authorized Jaguar dealer, please contact the Jaguar Customer Relationship Center at:
1 800 4JAGUAR (1-800-452-4827)
You can also contact Jaguar by e-mail: Visit the web site www.jaguarusa.com and send an email from the
"Contact Us" section.
If you have the need to contact Jaguar by mail, please use the following address:
Jaguar Cars
ATTN: Customer Relationship Center
555 MacArthur Boulevard
m
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Sincerely,
e
Mahwah, NJ 07430-2327
If you are still having difficulty getting your vehicle repaired in a reasonable time or without charge, you may
write the
Administrator, National Highway Traffic Safety Administration
400 Seventh Street, S.W.
Washington, D.C. 20590
Or you may call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153), or log on to
www.safercar.gov to submit a complaint electronically.
We appreciate your confidence in our product and wish to do everything we can to retain that confidence.
Jaguar in cooperation with your authorized dealer will strive to minimize any inconvenience to you caused by
this campaign.
sa
Benjamin I. Weiner
Customer Satisfaction Manager
Safety Recall R176: Technical Q & A
Main Message: An issue has been identified on certain 2005 model year Jaguar S-TYPE (X200) vehicles in
the VIN range from N05049 to N52047 specified with the Low Emission Vehicle Stage II (LEV II)
evaporative emissions system, where 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.
Q1
Who do I contact if a member of the press contacts me about this recall?
A
Please ensure that any Press enquiries are referred to the Jaguar Land Rover Corporate Affairs office.
Q2
Why is Jaguar Land Rover Limited recalling certain S-TYPE models?
A
Jaguar Land Rover Limited is conducting a voluntary safety recall involving certain 2005 model year
Jaguar S-TYPE vehicles to install a new fuel tank. This work will be carried out free of charge.
Q3
Can you tell me more about what is wrong with the vehicle?
A
Investigations have determined that 2005MY Federal vehicles may be fitted with a fuel tank that has
inadequate thickness around the apertures and/or dimension concerns that could lead to aperture
distortion around the seals. Where the tank aperture sealing is inadequate it is possible for the On
Board Diagnostic leak detection system to sense this and could result in illumination of the malfunction
indicator lamp (MIL) or a fuel odor. Fuel leaks are most likely to occur only after a fuel tank has been
fully filled.
Q4
How would the customer become aware of potentially having this concern?
A
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.
Q5
Does this recall affect vehicle safety?
A
Because most of the reports describing fuel leaks that Jaguar Land Rover Limited has received
indicate that the leaks occurred following refueling of the tank, it is advisable that customers refrain
from completely filling their fuel tanks.
Q6
How was the condition discovered?
A
This condition was discovered through routine analysis of warranty data.
Q7
Have there been any accidents or injuries?
A
There have been no fires, accidents or injuries of which we are aware.
Q8
Is the defect leading you to any concerns regarding the reliability of a system, which is
supposed to be designed and engineered for the passengers' safety? What type of measures
are you planning to take?
A
We have no concerns with the reliability of the fuel tank when it is manufactured to the correct
specification. This issue is a quality concern associated with manufacturing process of the fuel tank that
was manufactured away from specification by the fuel tank supplier. Appropriate additional safeguards
have been introduced at the supplier to prevent a recurrence of this manufacturing problem.
Q9
What will the authorized repairers do to the vehicles?
A
Authorized repairers will replace the fuel tank with a known good fuel tank.
Q10
Which vehicles are affected by this recall?
A
This concern affects 2005 Model Year S-TYPE vehicles that are fitted with the Low Emission Vehicle
Stage II (LEV II) evaporative emissions control system only. These vehicles are only specified for sale
in the United State of America and Canada. S-TYPE vehicles in all other markets are fitted with a
completely different fuel tank and are unaffected by this concern.
Q11
Are other Jaguar models affected by these actions?
A
No other Jaguar vehicles are affected by this action.
Q12
Are parts available to rework vehicles?
A
Parts will be available at campaign launch.
Q13
How much will the recall cost Jaguar Land Rover Limited?
A
Cost is never a factor in Jaguar Land Rover Limited decisions to recall vehicles.
Q14
How do I know if my S-TYPE vehicle is affected?
A
All owners of potentially affected vehicles will receive a letter shortly inviting them to contact a Jaguar
authorized repairer for the work to be carried out.
Q15
How long does it take for the car to be repaired?
A
The work to be carried out will vary in time depending on the vehicle type, but it is expected to be
completed in approximately five and one-half (5.5) hours. Naturally, due to workshop schedules,
vehicles may be required for longer.
Q16
Can I continue to drive my S-TYPE vehicle safely until it has been recalled?
A
If a customer is at all concerned about operating their vehicle in these conditions, our advice is to fill the
fuel tank no more than ¾ full.
Note: Please ensure that any Press enquiries are referred to the Jaguar Land Rover Corporate Affairs
office.