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SB-10057588-6294

TECHNICAL BULLETIN
LTB00566NAS4
10 OCT 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 Land
Rover service facility to determine whether this bulletin applies to a specific vehicle.

This reissue replaces all previous versions. Please destroy all previous versions.

Changes are highlighted in gray

SECTION: 310-01

Fuel Gauge Operation Inaccurate
AFFECTED VEHICLE RANGE:
LR4 (LA)
Model Year:
VIN:

2010-2013
AA510742-DA656034

LR2 (LF)
Model Year:
VIN:

2008-2012
8H000212-CH292666

Range Rover Sport (LS)
Model Year:
2010-2013
VIN:
AA212147-DA790997
Range Rover (LM)
Model Year:
2010-2012
VIN:
AA304426-CA369495

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.

NOTE: Advise the customer to bring the vehicle in with the fuel tank level below ¼ full.
Action: Should a customer express this concern, follow the Service Instruction outlined below.

PARTS:

CAUTION: The splice joint connector is specific to this repair and must be used and crimped using
special tool 418-116A / YRW500010.
LR050538

Splice joint connector

Quantity: 6

LR000966

Gasket - LR2, LR4, Range Rover Sport

Quantity: 1

ESR3806

Gasket - Range Rover

Quantity: 2

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TOOLS:
Crimping pliers
418-116A / YRW500010

WARRANTY:
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.
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

DESCRIPTION

SRO

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

NOTE: Normal Warranty procedures apply.

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.

3.

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

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always correct.
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.

4.

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.
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.

6.

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.
Using Crimping Tool 418-116A / YRW500010,
install and crimp a splice to the ends of each wire.

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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.

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10.
CAUTION: Make sure the wiring is cut
as close to the connector as possible.
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.

12.
NOTE: Do not connect the two splices
until step 16.
Using Crimping Tool 418-116A / YRW500010,
install and crimp a splice to the end of each wire.

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13.

CAUTION: Do not install the fuel tank flange at this point.

Install the fuel pump and sender unit / fuel pump module into the fuel tank (see TOPIx Workshop Manual,
Section 310-01).

14.
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.
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.

15.
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.
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

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wire.
Using a suitable tie strap, secure the two

splices together.

16.
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.
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.

18.
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.
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).

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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

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