Fuel Gauge Operation Inaccurate (LTB00566V6)

FUEL GAUGE OPERATION INACCURATE

TECHNICAL SERVICE BULLETIN

MARKETS

NAS

CONDITION SUMMARY

Situation:  The fuel gauge may be inoperative or inaccurate.

Cause:  These issues may be caused by fretting corrosion across the fuel sender harness pins inside the fuel tank.

Action:  Should a customer express this concern, follow the Service Instruction outlined below.

PARTS

LR050538	Splice joint connector	Quantity: 6
LR000966	Gasket - LR2, LR4, Range Rover Sport	Quantity: 1
ESR3806	Gasket - Range Rover	Quantity: 2

TOOLS

Crimping pliers

WARRANTY

DESCRIPTION	SRO	TIME (HOURS)	CONDITION CODE	CAUSAL PART
Fuel sender harness modification - LR2 (L359)	88.25.89/35	2.6	X2	LR038723
Fuel sender harness modification - LR4 (L319)	88.25.89/35	1.5	X2	LR042971
Fuel sender harness modification - Range Rover Sport (L320)	88.25.89/35	1.5	X2	LR042716
Fuel sender harness modification - Range Rover (L322)	88.25.89/35	1.5	X2	LR043153

SERVICE INSTRUCTION

1. Remove the fuel pump and sender unit/fuel pump module (see TOPIx Workshop Manual, Section 310-01).
2. Place the fuel pump and sender unit/fuel pump module on a clean work surface.
   CAUTION: To reduce the chance of incorrect wiring of the harnesses, wherever possible, only repair one wire at a time.
   CAUTION: Make sure that the splice is crimped in the correct location.
   CAUTION: Make sure that the splice is crimped using special tool 418-116A/YRW500010.
   CAUTION: Make sure that the splice with the part number listed above is used. Failure to follow these instructions may result in a poor repair.
   NOTE: The number of black connectors shown in the fuel tank on a vehicle may vary from the procedure shown below. To achieve the best possible repair, replace as many of the black connectors (up to three [3 in total) as possible.
   NOTE: Some variation in the illustrations may occur, but the essential information is always correct.
3. When installing the splices, make sure that the splice is crimped in the correct location.
   • 'Tick'/'1'  - correct crimp location.
   • 'X'/'2'  - incorrect crimp location.
   CAUTION: Make sure the wiring is cut as close to the connector as possible.
   NOTE: A total of three (3) black two-pin connectors may be found. Replace only one at a time.
4. Identify a black two-pin connector to be removed.
   • Cut wiring as close to the connector as possible.
5. Using a suitable tool, remove 5mm of insulation from the end of each wire.
   CAUTION: After crimping the connection, perform a gentle pull test to make sure that a sufficiently strong connection has been created. If required, remove and replace the splice.
6. Using Crimping Tool 418-116A/YRW500010, install and crimp a splice to the ends of each wire.
7. Repeat steps 5-6 to the other wire in the connector.
   • Discard the connector.
8. Repeat steps 4-7 to all black two-pin connectors (up to three [3] in total).
9. Using a suitable tie strap, secure the two splices together.
   CAUTION: Make sure the wiring is cut as close to the connector as possible.
10. Identify the ground connector (two black wires) to be removed.
    • Cut wiring as close to the connector as possible.
    • Discard the connector.
11. Using a suitable tool, remove 5mm of insulation from the end of each wire.
    NOTE: Do not connect the two splices until step 16.
12. Using Crimping Tool 418-116A/YRW500010, install and crimp a splice to the end of each wire.
    CAUTION: Do not install the fuel tank flange at this point.
13. Install the fuel pump and sender unit/fuel pump module into the fuel tank (see TOPIx Workshop Manual, Section 310-01).
    CAUTION: Make sure the wiring is cut as close to the connector as possible.
    CAUTION: Make sure that the correct wires are re-connected to each other.
14. Identify the connector to be removed.
    • Carefully withdraw the connector out of the tank.
    • Cut the wires shown as close to the connector as possible.
    • Discard the connector.
    CAUTION: After crimping the connection, perform a gentle pull test to make sure that a sufficiently strong connection has been created. If required, remove and replace the splice.
15. Using a suitable tool, remove 5mm of insulation from the end of each wire.
    • Using Crimping Tool 418-116A/YRW500010, install and crimp a splice to the ends of each wire.
    • Using a suitable tie strap, secure the two splices together.
    CAUTION: After crimping the connection, perform a gentle pull test to make sure that a sufficiently strong connection has been created. If required, remove and replace the splice.
16. Connect the two ground wires from the base of the fuel tank flange to the two splices installed in step 12.
    • Position the fuel tank flange close to the fuel tank.
    • Using a suitable tool, remove 5mm of insulation from the end of each wire.
    • Using Crimping Tool 418-116A/YRW500010, install and crimp a splice to the ends of each wire.
    • Using a suitable tie strap, secure the two splices together.
17. Measure the resistance values of the fuel gauge sending units.
    • Compare the resistance values obtained to the Resistance Values Checks chart below.
      • If the resistance values are correct, continue to the next step.
      • If the resistance values are not correct, further diagnosis is required. Must be performed as a separate claim.
    CAUTION: A successful resistance values check (step 17) must be carried out before continuing to install the fuel pump and sender unit/fuel pump module.
18. Complete the installation of the fuel pump and sender unit/fuel pump module (see TOPIx Workshop Manual, Section 310-01).
19. Read and clear all Diagnostic Trouble Codes (DTC).

Resistance Values Checks

Check No.	Pin No.		Lower Resistance Value (Ohms)	Upper Resistance Value (Ohms)
1	1	2	46.2	1002.2
2	1	6	46.2	1002.2