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TECHNICAL BULLETIN
LTB00566NAS2
06 JAN 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. Only refer to the
electronic version of this Technical Bulletin in TOPIx.

Changes are highlighted in gray

SECTION: 310-00

Fuel Gauge Operation / DTC U0128-00 Stored
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:

NOTE: This bulletin supersedes all versions of LTB00304NAS.
Situation: The fuel gauge may experience one or more of the following issues:
• LR4, Range Rover Sport only: Diagnostic Trouble Code (DTC) U0128-00 stored in the
Instrument Cluster (IC);
• Fuel gauge inoperative;
• Fuel gauge not showing more than half full;
• Fuel gauge fluctuates; and/or
• Fuel gauge switches on/off intermittently.

Cause: These issues may be caused by:

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• LR4, Range Rover Sport only: Software issue within the Instrument Cluster (IC).
• Backed-out pins in any of the following areas: internal to the fuel tank (sender wiring), fuel
pump module, and/or fuel tank flange assembly.
• Fretting corrosion across the fuel sender harness pins inside the fuel tank (black connectors).

NOTE: LR4, Range Rover Sport only: If Diagnostic Trouble Code (DTC) U0128-00 is present,
update the Instrument Cluster (IC) software using IDS-DVD133.02 v128 or later. If the fuel gauge
then reads correctly, release the vehicle. If DTC U0128-00 remains after updating the IC software,
refer to the Service Instruction outlined below.

NOTE: Refer to TOPIx Workshop Manual, Section 310-01: Fuel Tank and Lines Diagnosis and
Testing; if a harness or fuel sender fault cannot be identified, follow the Service Instruction outlined
below.
Action: Should a customer express this concern, follow the appropriate 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 (as
necessary)

LR000966

Gasket - LR2, LR4, Range Rover Sport

Quantity: 1 (as
necessary)

ESR3806

Gasket - Range Rover

Quantity: 2 (as
necessary)

TOOLS:

NOTE: This document is an 'Active Bulletin' that will display a functional programming shortcut if
accessed within a diagnostic session using SDD.

SDD with latest DVD and Calibration File; first available on DVD133.02 v.128
Jaguar Land Rover-approved Midtronics battery power supply
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.
DESCRIPTION

SRO

TIME
(HOURS)

CONDITION
CODE

CAUSAL
PART

Fuel sender harness modification - LR2

88.25.89/35

2.6

X2

LR042971

Fuel sender harness modification - LR4

88.25.89/35

1.5

X2

LR042716

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Fuel sender harness modification - Range
Rover Sport

88.25.89/35

1.5

X2

LR050538

Fuel sender harness modification - Range
Rover

88.25.89/35

1.5

X2

LR050538

Update Instrument Cluster software - LR4,
Range Rover Sport

88.90.04

0.2

X2

LR042971

NOTE: Normal Warranty policies and procedures apply.

SERVICE INSTRUCTION 1:
SERVICE INSTRUCTION 1 applies to the following model / VINs only:
LR4: AA510742-DA656034
Range Rover Sport: AA212147-DA790997

1.

CAUTION: A Jaguar Land Rover-approved Midtronics battery power supply must be connected
to the vehicle battery during SDD diagnosis / module programming.

NOTE: IDS must be loaded with DVD133.02 v.128 or later.
Connect the Jaguar Land Rover-approved Midtronics battery power supply to the vehicle battery.
2. Turn ignition 'ON' (engine not running).
3. Connect the Symptom Driven Diagnostics (SDD) to the vehicle and begin a new session.
4. Follow the on-screen prompts, allowing SDD to read the VIN and identify the vehicle and initiating the data
collect sequence.
5. Select 'Diagnosis' from the Session Type screen.
6. Select the 'Selected Symptoms' tab, and then select the following:
Electrical > Instruments > Gauges > Fuel gauge

7. Select the 'Related' DTC view Tab and view the DTCs.
If Instrument Cluster (IC) DTC U0128-00 is present, continue to step 8.
If Instrument Cluster (IC) DTC U0128-00 is not present, exit the current SDD session, disconnect the SDD

and battery power supply, and continue to step 14.
8. Select 'continue'.
9. Select the 'Recommendations' tab, and then select 'Run' to perform the 'Configure existing module –
Instrument cluster control module' option.
10. Follow all on-screen instructions to complete this task.
11. Check fuel gauge operation:
If the fuel gauge operates correctly, no further action required; return vehicle to customer.
If the fuel gauge does not operate correctly, continue to step 14.

12. Exit the current session.
13. Disconnect the SDD and the battery power supply from the vehicle.

SERVICE INSTRUCTION 2:

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SERVICE INSTRUCTION 2 applies to the following model / VINs only:
LR2: 8H000212-CH292666
LR4: AA510742-BA595923
Range Rover Sport: AA212147-BA712004
Range Rover: AA304426-CA369495

1. Lower the fuel tank for access (see TOPIx Workshop Manual, Section 310-01).
2. Check the body harness-to-fuel-tank-connector integrity:
With the ignition OFF, pull the connector 'up'.
Turn the ignition ON.

• Does the fuel gauge drop to '0' (empty)?
• Repeat several times.
• If the fuel gauge does not drop, continue with the diagnostics in TOPIx Workshop Manual, Section
310-01: Fuel Tank and Lines Diagnosis and Testing.
• If the fuel gauge drops, remove the connector and ensure pin connections are not loose and are
correctly retained in the housing.
• Repair as necessary.
3. Remove the fuel pump and sender unit / fuel pump module (see TOPIx Workshop Manual, Section 310-01).

4.

NOTE: Typical in-tank fuel module and
sender components; not all derivatives will
have the same number of connectors.
Place the fuel pump and sender unit / fuel pump
module on a clean work surface.

5.

NOTE: All internal wiring must be checked.
Check the internal components for backed out pins/wires.
If no backed-out pins/wires are found, continue to the next step.
If any backed-out pins/wires are found, repair as necessary.

6. Using SDD, measure the resistance of the fuel gauge sending units.
7. Compare values to the resistance chart (see TOPIx Workshop Manual, Section 310-01).
If the sending units resistance value is correct, continue to the next step.
If the sending units resistance value is not correct, replace the faulty units. Must be performed as a

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separate claim.

8.

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.
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.

9.

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.

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10. Using a suitable tool, remove 5mm of insulation
from the end of each wire.

11.
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.

12. Repeat steps 10-11 to the other wire in the
connector.
Discard the connector.

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13. Repeat steps 9-13 to all black two-pin connectors (up to three [3] in total).
14. Using a suitable tie strap, secure the two splices
together.

15.
CAUTION: Make sure the wiring is cut
as close to the connector as possible.
Identify the ground connector (two black wires) to
be removed.

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Cut wiring as close to the connector as

possible.
Discard the connector.

16. Using a suitable tool, remove 5mm of insulation from the end of each wire.

17.
NOTE: Do not connect the two splices
until step 21.
Using Crimping Tool 418-116A / YRW500010,
install and crimp a splice to the end of each wire.

18.

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).

19.
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.

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Carefully withdraw the connector out of the

tank.
Cut the wires shown as close to the connector

as possible.
Discard the connector.

20.
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
wire.
Using a suitable tie strap, secure the two
splices together.

21.
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
17.
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.

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Using a suitable tie strap, secure the two

splices together.

22. Measure the resistance values of the fuel gauge sending units.
23. Compare the resistance values to the resistance chart (see TOPIx Workshop Manual, Section 310-01).
If the sending units resistance value is correct, continue to the next step.
If the sending units resistance value is not correct, further diagnosis is required. Must be performed as a

separate claim.

CAUTION: A successful resistance values check (step 20) must be carried out before
24.
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).
25. Read and clear all Diagnostic Trouble Codes (DTC).

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