JTB00373NAS2

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TECHNICAL BULLETIN
JTB00373NAS2
12 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.
This reissue replaces all previous versions. Please destroy all previous versions. Only refer to the
electronic version of this Technical Bulletin in TOPIx.
Changes are highlighted in gray
SECTION: 310-01
Fuel Tank Service Fix
AFFECTED VEHICLE RANGE:
S-TYPE (X200)
Model Year:
VIN:
2005
N05051-N52047
Engine:
3.0L NA V6 - AJ27
V8 4.2L Petrol
MARKETS:
NAS
CONDITION SUMMARY:
Situation: Due to a change in design, the fuel tank has a new service part. Should the existing fuel tank require
replacement, it will be necessary to perform a conversion so the new service part can be used. This conversion is
only necessary once; for any possible future repairs to the fuel tank, only the affected components will require
repair / replacement.
Cause: This is due to a change in fuel tank design.
Action: If fuel tank replacement is required, follow the Service Instruction outlined below.
PARTS:
C2Z29213
(Item 1) Fuel tank
Quantity: 1
C2Z23192
(Item 2) Fuel pump
Quantity: 1
C2D25076
(Item 3) Flange
Quantity: 1
C2Z7361
(Item 4) Gasket
Quantity: 1
C2Z7352
(Item 5) Fuel pump retaining ring
Quantity: 1
C2Z8500
(Item 6) Pipe - fuel feed
Quantity: 1
C2Z21711
(Item 7) Tank strap - Left
Quantity: 1
C2Z21684
(Item 8) Tank strap - Right
Quantity: 1
C2Z10210
(Item 9) Heatshield
Quantity: 1
C2Z4771
(Item 10) Hose - fuel filler
Quantity: 1
XR858662
(Item 11) Heat-sleeve
Quantity: 1
XR858628
(Item 12) Evaporator pipe
Quantity: 1
XR858626
(Item 13) Fuel tank wiring harness
Quantity: 1
AAU5884J
(Item 14) Cable tie - 150mm (L) X 2mm (W)
Quantity: 8
XR857854
(Item 15) M6 nut with flange (Ground wire fixing)
Quantity: 1
XR858627
(Item 16) Ground lead
Quantity: 1
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XR858630
XR858629
(Item 17) Suitable tape (to be sourced locally)
Quantity: 1
(Item 18) Instrument Cluster
Quantity: 1
(Item 19) Resistor box
Quantity: 1
(Item 20) Suitable sealant (to be sourced locally)
Quantity: 1
TOOLS:
Remove/Install Locking Ring, Fuel Tank.
310-123
WARRANTY:
NOTE: Vehicles eligible for Safety Recall R176 must be repaired under that program.
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 TOPIx to obtain the latest repair
time.
NOTE: DDW requires the use of causal part numbers. Labor only claims must show the causal part
number with a quantity of zero.
DESCRIPTION
SRO
TIME (HOURS)
CONDITION CODE
CAUSAL PART
Fuel tank service fix
19.92.08
5.3
01
C2Z2913
NOTE: Normal Warranty policies and procedures apply.
SERVICE INSTRUCTION:
This Service Instruction is applicable to 3.0L V6 / 4.2L naturally aspirated engine vehicles ONLY. Refer to
JTB00372 for 4.2L Supercharged V8 vehicles.
NOTE: Vehicles eligible for Safety Recall R176 must be repaired under that program.
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
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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).
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.
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.
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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).
17. Install the new fuel tank wiring harness (Item
13).
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 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).
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.
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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.
24. Pass the ground lead (Item 16) through the
existing body grommet into the vehicle.
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25. Using a suitable cable tie (Item 14), secure the
ground lead.
26. Remove the wiring harness clip.

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

 Torque to 2Nm.
27. Install the wiring harness clip.
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28. Using suitable cable ties (Item 14), secure the
wiring harness.
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 right-hand
fuel tank strap (Item 8).
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34. Using a suitable cable tie (Item 14), secure the
wiring harness.
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35. Install floor aperture cover.
36. Install the rear seat cushion (see TOPIx Workshop Manual, Section 501-10).
NOTE: Note the current vehicle mileage prior to installing the new Instrument Cluster (IC);
37.
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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