JTB00373NAS2 Service Bulletin/Repair Instructions

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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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