R176NAS5

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TECHNICAL BULLETIN
R176NAS5
18 AUG 2014
© Jaguar Land Rover North America, LLC
NOTE: The information in Technical Bulletins is intended for use by trained, professional Technicians with the knowledge, tools,
and equipment required to do the job properly and safely. It informs these Technicians of conditions that may occur on some
vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by 'do-ityourselfers'. If you are not a Retailer, do not assume that a condition described affects your vehicle. Contact an authorized
Jaguar service facility to determine whether this bulletin applies to a specific vehicle.
SECTION: 310-01
Safety Recall: Fuel Tank Replacement
AFFECTED VEHICLE RANGE:
S-TYPE (X200)
Model Year:
VIN:
2005
N05049-N52047
MARKETS:
NAS
CONDITION SUMMARY:
NOTE: Changes are significant and therefore not highlighted.
Situation: A concern has been identified with fuel tanks fitted to 2005MY Jaguar S-TYPE (X200) vehicles
specified with the Low Emission Vehicle Stage II (LEV II) evaporative emissions system. Affected vehicles may
contain the fuel delivery module (FDM), jet pump module (JPM), and/or cluster valve seals located on 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 0.5mm diameter and illuminate the amber Malfunction Indicator Lamp (MIL) on the Instrument
Cluster. If the fuel tank is full or the vehicle is parked on a hill with a leak path present, the driver may notice
fuel odor or fuel leakage.
Action: Retailers are required to HOLD all affected vehicles that are within your control until completion of the
appropriate Service Instruction (A or B) outlined below to replace the fuel tank.
PARTS:
TABLE 1 - 4.2L V8 Supercharged Vehicles Only
PART No. / SUNDRY CODE 'ITEM' No.
DESCRIPTION
QTY. / VALUE
C2Z29212
1
Fuel tank
1
C2D25079
2
Fuel pump module
1
C2D25076
3
Flange
1
C2Z7361
4
Gasket
1
C2Z7352
5
Retaining ring
1
C2Z8500
6
Pipe - fuel feed
1
C2Z21711
7
Strap - tank - left-hand
1
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C2Z21684
8
Strap - tank - right-hand
1
C2Z10210
9
Heatshield
1
C2Z4771
10
Hose - fuel filler
1
XR858662
11
Heat-sleeve
1
XR858628
12
Evaporator pipe
1
XR858660
13
Fuel pump control module (ECU)
1
XR858670
14
Fuel tank harness
1
AAU5884J
15
Cable tie - 50mm (L) X 2mm (W)
8
C2C8870
16
M6 nut with flange
2
C2D13865
17
M5 nut with flange
2
XR858671
18
Cabin overlay wiring harness
1
-
19
20
-
Suitable tape (locally sourced)
RTV silicon sealant (locally sourced)
Four (4) 150mm-length cable ties (locally sourced)
*$5.00
*An allowance of $5.00 has been allocated to cover the cost of locally sourced tape, RTV silicon sealant, and four (4)
150mm-long cable ties.
Displaced tanks MUST be rendered unusable and safely disposed of in accordance with local policies and procedures.
For reimbursement 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
PART No. / SUNDRY CODE 'ITEM' No.
DESCRIPTION
QTY. / VALUE
C2Z29213
1
Fuel tank
1
C2Z23192
2
Fuel pump module
1
C2D25076
3
Flange
1
C2Z7361
4
Gasket
1
C2Z7352
5
Fuel pump retaining ring
1
C2Z8500
6
Pipe - fuel feed
1
C2Z21711
7
Strap - tank - left-hand
1
C2Z21684
8
Strap - tank - right-hand
1
C2Z10210
9
Heatshield
1
C2Z4771
10
Hose - fuel filler
1
XR858662
11
Heat-sleeve
1
XR858628
12
Evaporator pipe
1
XR858626
13
Fuel tank wiring harness
1
AAU5884J
14
Cable tie - 50mm (L) X 2mm (W)
8
XR857854
15
M6 nut with flange (ground wire fixing)
1
XR858627
16
Ground lead
1
-
17
Suitable tape (locally sourced)
*
XR858630
18
Instrument Cluster
1
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XR858629
19
Resistor box
1
-
20
-
RTV silicon sealant (locally sourced)
Four (4) 150mm-length cable ties (locally sourced)
*$5.00
*An allowance of $5.00 has been allocated to cover the cost of locally sourced tape, RTV silicon sealant, and four (4)
150mm-long cable ties.
Displaced tanks MUST be rendered unusable and safely disposed of in accordance with local policies and procedures.
For reimbursement of disposal costs, please refer to the Related Damage section within the Warranty information.
SPECIAL TOOLS:
Refer to Workshop Manual / Service Instruction for any required tools
WARRANTY:
NOTE: Check DDW to ensure that a 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. The SRO and part information listed have been included for information only. The Option Code(s) that allows
for the drive in / drive out allowance may 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
OPTION
CODE
DESCRIPTION
SRO
TIME
PARTS /
(HOURS) SUNDRY CODE
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
19.92.08 5.0
10.10.10 0.1
C2Z29212
C2D25079
C2D25076
C2Z7361
C2Z7352
C2Z8500
1
1
1
1
1
1
NOTE: 4.2L V8
Supercharged vehicles only
Fuel tank - Renew
R176
U
NOTE: 4.2L V8
Supercharged vehicles only
Fuel tank - Renew
QTY. /
VALUE
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Drive in/drive out
R176
C2Z21711
C2Z21864
C2Z10210
C2Z4771
XR858662
XR858628
XR858660
XR858670
AAU5884J
C2C8870
C2D13865
XR858671
Other
1
1
1
1
1
1
1
1
8
2
2
1
$5.00
19.92.08 5.3
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
19.92.08 5.3
10.10.10 0.1
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
V
NOTE: 3.0L V6 / 4.2L V8
naturally aspirated vehicles
only
Fuel tank - Renew
R176
W
NOTE: 3.0L V6 / 4.2L V8
naturally aspirated vehicles
only
Fuel tank - Renew
Drive in/drive out
R176
Y
An allowance of $5.00 has been allocated to cover the cost of locally sourced duct tape, RTV silicon sealant, and four
(4) 150mm-long cable ties.
Displaced tanks MUST be rendered unusable and safely disposed of in accordance with local policies and procedures.
For reimbursement of disposal costs, please refer to the Related Damage section within the Warranty information.
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 actual disposal costs against Sundry Code
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'Other', and quote the value in local currency.
PROGRAM
CODE
OPTION
CODE
R176
X
DESCRIPTION
Reimbursement of fuel tank
disposal
SRO
-
TIME
(HOURS)
-
PARTS /
SUNDRY CODE
Other
QTY. / VALUE
Dealer entered
value
Normal Warranty policies and procedures apply
SERVICE INSTRUCTION A - 4.2L V8 Supercharged Vehicles Only
NOTE: Refer to Parts for 'Item' information.
1. Remove the rear seat cushion (see TOPIx Workshop Manual, Section 501-10).
2. Remove the rear seat right-hand bolster (see TOPIx Workshop Manual, Section 501-10).
3. Remove the floor aperture cover.
4. Remove the existing fuel tank assembly (see TOPIx Workshop Manual, Section 310-01).
5. Remove fuel tank supply pipe from existing tank assembly and retain for reinstallation.
6. Remove and discard the fuel tank heat shield.
7. Remove and discard the fuel tank securing straps.
8. Remove and discard the fuel filler link hose.
9.
NOTE: To achieve correct reading on
the Instrument Cluster, make sure to
connect to the new fuel pump module.
Failure to do this will give a false or
incorrect reading on the Instrument
Cluster.
Install the new fuel pump (Item 2) to the new
tank (Item 1).
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10.
NOTE: A new gasket MUST be
installed (Item 4).
NOTE: Note the route of the wiring
harness when fitting the new fuel pump;
failure to do this may give a false or
incorrect reading on the Instrument Cluster.
Connect the fuel pump wiring harness electrical
connector to the flange electrical connector (Item
3).
11. Using special tool 310-123, secure fuel tank retaining ring (Item 5) to the fuel tank flange (Item 3).
12.
NOTE: pin location as viewed from the
rear of the electrical connector.
Carry out a fuel tank sender unit resistance test.
13. Carry out an electrical test to make sure the
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fuel tank sender unit reads correctly.

 Temporarily connect the wiring harness
electrical connector to the fuel tank flange.

 Using a suitable multi-meter, check the
resistance between pin 9 Brown/Red and pin 5
White/Red; approximately 50 Ohms with an
empty tank.

 Using a suitable multi-meter, check the
resistance between pin 9 Brown/Red and pin 6
White/Blue; approximately 50 Ohms with an
empty tank.
14. Turn the tank upside down to fully extend the fuel level sender float.
15. Using a suitable multi-meter, check the
resistance between pin 9 Brown/Red and pin 5
White/Red; approximately 984 Ohms with an
empty tank.
16. Using a suitable multi-meter, check the
resistance between pin 9 Brown/Red and pin 6
White/Blue; approximately 460 Ohms with an
empty tank.

 Once the resistance checks have been
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completed, disconnect the fuel tank wiring
harness connector from the fuel tank flange;
this will be connected in step 60.
17. Install the new evaporator pipe (Item 12) to the
new fuel tank (Item 1).
18. Install the new fuel tank wiring harness (Item
14).

 Using suitable tape (Item 19), secure the fuel
tank wiring harness to the fuel tank (Item
14).
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19. Install the existing fuel feed pipe to the new
fuel tank (Item 1).
20. Install heat sleeve (Item 11) over the fuel tank
filler hose (Item 10).
21. Install the new fuel tank filler hose to fuel filler neck.
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22. Install harness blanking plug (supplied with
item 14) to the existing redundant connector and
secure to the body.
23. Take the new fuel tank strap brackets (Items 7
and 8) and:

 using a suitable 6.5mm drill bit, drill the right-
hand strap bracket (Item 8);

 loosely fit both straps to the heelboard and
allow to hang.
24. Install the new fuel tank heat shield (Item 9).
25. Using a suitable tool, make a hole 45mm in the
floor aperture cover.
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26. Remove the rear seat right-hand bolster
bracket.
27. Remove the luggage compartment rear righthand trim.
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28. Position cabin overlay wiring harness loosely in
position (Item 18).
29. Remove the existing fuel pump ECU.
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30. Remove for access the fuel pump ECU mounting
bracket.
31. Disconnect the harness connectors from Rear
Electronic Module (REM).
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32. Splice new overlay harness to existing vehicle harness (see TOPIx Workshop Manual, Section 418-02).

 Carry out steps 32-46.
33.
NOTE: Remove only a suitable amount
of wiring harness insulation as required to
access the wiring.
NOTE: Make the cut as close to the base
as possible to give maximum length to carry
out the splice.
Cut Red wire (CA101 pin 11).
34. Using the supplied butt connector, connect the
Red wire (CA101 pin 11) to the new overlay
harness Grey/Yellow wire.

 Using a suitable tool, crimp the connector for
Grey/Yellow to Red (pin 11 in CA101).
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35. Cut Yellow wire (CA101 pin 12)
36. Using the supplied butt connector, connect the
Yellow wire (CA101 pin 12) to the new overlay
harness Brown/White wire.

 Using a suitable tool, crimp the connector for
Yellow to Brown/White (pin 12 in CA101).
37. Cut White/Red wire (CA101 pin 15).
38. Using the supplied butt connector, connect the
White/Red wire (CA101 pin 15) to the new
overlay harness White/Red (labeled for the
CA101connector) wire.

 Using a suitable tool, crimp the connector for
White/Red to White/Red (pin 15 in CA101).
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39. Cut White/Blue wire (CA101 pin 16).
40. Using the supplied butt connector, connect the
White/Blue wire (CA101 pin 16) to the new
overlay harness White/Blue (labeled for the
CA101connector) wire.

 Using a suitable tool, crimp the connector for
White/Blue to White/Blue (pin 16 in CA101).
41. Cut Brown/Red wire (CA103 pin 23).
42. Using the supplied butt connector, connect the Brown/Red wire (CA103 pin 23) to the new overlay harness
Brown/Red (labeled for the CA103 connector) wire.

 Using a suitable tool, crimp the connector for Brown/Red to Brown/Red (pin 23 in CA103).
43.
NOTE: ‘T’ splice connection; both ends of the original harness must be connected to the
overlay harness.
Remove a section of insulation from the White/Blue wire (CA103 pin 19) to make a ‘T’ splice.
44. Remove a section of insulation from the White/Blue wire (CA103 pin 19) to make a ‘T’ splice.
45. Using the supplied butt connector, connect the
White/Red wire (CA109 pin 19) in a ‘T’ splice to
the new overlay harness White/Red (labeled for
the CA103connector) wire.

 Using a suitable tool, crimp the connector for
White/Red to White/Red (pin 19 in CA103).
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46. Using suitable electrical tape, insulate the
wiring harness and position the wiring harness to
one side.
47. Install the fuel pump ECU mounting bracket.
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48. Connect ground lead from overlay harness
(Ground C156).
49.
NOTE: Fixings are different sizes 5mm
and 6mm.
Install new ECU module.

 Secure using 2 x M5 nuts (Item 17) and 2 x
M6 nuts (Item 16).

 Torque to 5Nm.
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50. Connect Link harness to the new fuel pump ECU
(Item 18).
51. Connect Link harness (male connector) to the
original fuel pump ECU harness connector
(CA283).
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52. Make sure that all of the harnesses are secured.
53. Using suitable cable ties (Item 15), install the
cabin overlay wiring harness (Item 18).
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54. Install the rear seat right-hand bolster bracket.

 Torque to 11Nm
55. Install the rear seat right-hand bolster (see TOPIx Workshop Manual, Section 501-10).
56. Install the luggage compartment rear righthand trim.
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57.
NOTE: Position the wiring harness to
one side prior to the installation of the new
fuel tank.
Install fuel tank (see TOPIx Workshop Manual,
Section 310-01).
58. Using a suitable cable tie (Item 15), secure the
existing vehicle harness to the right tank strap
bracket (Item 8).
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59. Secure the electrical connectors to the right
tank strap bracket (Item 8).
60. Connect the fuel tank sender unit electrical
connector to the fuel tank sender unit.
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61. Install overlay wiring harness and wiring
harness grommet to floor aperture cover.

 Using a suitable adhesive (Item 20), glue the
wiring harness grommet to the floor aperture
cover.
62. Install the rear seat cushion (see TOPIx Workshop Manual, Section 501-10).
63. Add fuel to the fuel tank and confirm fuel pump and fuel gauge operation.
SERVICE INSTRUCTION B - 3.0L V6 / 4.2L V8 Naturally Aspirated Vehicles
Only
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NOTE: Refer to Parts for 'Item' information.
1. Remove the rear seat cushion (see TOPIx Workshop Manual, Section 501-10).
2. Remove the floor aperture cover.
3. Remove existing fuel tank assembly (see TOPIx Workshop Manual, Section 310-01).
4. Remove fuel tank supply pipe from existing tank assembly and retain for reinstallation.
5. Remove and discard the fuel tank heat shield.
6. Remove and discard the fuel tank securing straps.
7. Remove and discard the fuel filler link hose.
8.
NOTE: To achieve correct reading on
the Instrument Cluster, make sure to
connect to the new fuel pump module.
Failure to do this will give a false or
incorrect reading on the Instrument
Cluster.
Install the new fuel pump (Item 2) to the new
tank (Item 1).
9.
NOTE: A new gasket MUST be installed
(Item 4).
NOTE: Note the route of the wiring
harness when fitting the new fuel pump;
failure to do this may give a false or
incorrect reading on the Instrument Cluster.
Connect the fuel pump wiring harness electrical
connector to the flange electrical connector (Item
3).
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10. Using special tool 310-123, secure fuel tank retaining ring (Item 5) to the fuel tank flange (Item 3).
11.
NOTE: pin location as viewed from the
rear of the electrical connector.
Carry out a fuel tank sender unit resistance test.
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12. Carry out an electrical test to make sure the
fuel tank sender unit reads correctly.

 Using a suitable multi-meter, check the
resistance between pin 9 Brown/Red and pin 5
White/Red; approximately 50 Ohms with an
empty tank.

 Using a suitable multi-meter, check the
resistance between pin 9 Brown/Red and pin 6
White/Blue; approximately 50 Ohms with an
empty tank.
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13. Turn the tank upside down to fully extend the fuel level sender float.
14. Using a suitable multi-meter, check the
resistance between pin 9 Brown/Red and pin 5
White/Red; approximately 984 Ohms with an
empty tank.
15. Using a suitable multi-meter, check the
resistance between pin 9 Brown/Red and pin 6
White/Blue; approximately 460 Ohms with an
empty tank.
16. Install the new evaporator pipe (Item 12) to the
new fuel tank (Item 1).
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17. Install the new fuel tank wiring harness (Item
13).

 Using suitable tape (Item 17), secure the fuel
tank wiring harness to the fuel tank (Item
13).

 Connect the fuel tank sender unit electrical
connector (Item 13) to the fuel tank sender
unit (Item 3).
18. Install the existing fuel feed pipe to the new
fuel tank (Item 1).
19. Install heat sleeve (Item 11) over the fuel tank
filler hose (Item 10).
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20. Install the new fuel tank filler hose to fuel filler neck.
21. Take the new fuel tank strap brackets (Items 7
and 8) and:

 using a suitable 6.5mm drill bit, drill the right-
hand strap bracket (Item 8);

 loosely install both straps to the heelboard
and allow to hang.
22. Install the new fuel tank heat shield (Item 9).
23. Using a suitable tool, make a small cut in the
existing body grommet to allow the ground lead
(Item 16) to pass through.
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24. Pass the ground lead (Item 16) through the
existing body grommet into the vehicle.
25. Using a suitable cable tie (Item 14), secure the
ground lead.
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26. Remove the wiring harness clip.

 Secure ground lead eyelet using M6 nut (Item
15).

 Torque to 2Nm.
27. Install the wiring harness clip.
28. Using suitable cable ties (Item 14), secure the
wiring harness.
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29. Using a suitable sealant (Item 20), seal the
wiring harness to the body grommet.
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30. Install the Resistor box (Item 19) secure to the
body using the clip attached to the electrical
connector.

 Connect Resistor box (Item 19) to Fuel tank
wiring harness (Item 13).
31.
CAUTION: Position the wiring harness
to one side prior to the installation of the
new fuel tank.
Install the new fuel tank (see TOPIx Workshop
Manual, Section 310-01).
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32. Using a suitable cable tie (Item 14), secure the
vehicle wiring harness to the right-hand fuel tank
strap bracket (Item 8).
33. Install the fuel tank connectors to the righthand fuel tank strap (Item 8).
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34. Using a suitable cable tie (Item 14), secure the
wiring harness.
35. Install floor aperture cover.
36. Install the rear seat cushion (see TOPIx Workshop Manual, Section 501-10).
37.
NOTE: Note the current vehicle mileage prior to installing the new Instrument Cluster (IC);
this must be uploaded into the new Instrument Cluster.
Install new Instrument Cluster (see TOPIx Workshop Manual, Section 413-01).
38. Add fuel to the fuel tank and confirm fuel pump and fuel gauge operation.
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