Land Rover Defender: Fuel Tank and Lines - Diagnosis and Testing

DIAGNOSIS AND TESTING

PRINCIPLES OF OPERATION

For a detailed description of the Fuel Tank and Lines, refer to the relevant Description and Operation section in the workshop manual.

INSPECTION, VERIFICATION AND ADDITIONAL WARNINGS FOR ELECTRIC VEHICLES

WARNINGS:

• A risk assessment must be performed before any work is undertaken. Failure to comply with this instruction may result in personal injury or death.
• All electric vehicle work must be performed by a suitably qualified person. Failure to comply with this instruction may result in personal injury or death.
• Appropriate Personal Protection Equipment (PPE) must be worn when working on or near an electric vehicle high voltage system. Failure to comply with this instruction may result in personal injury or death.
• The hybrid/EV battery pack casing must not be disassembled due to the risk of exposure to hazardous voltage. Failure to comply with this instruction may result in personal injury or death.
• The electric power inverter converter casing must not be disassembled due to the risk of exposure to hazardous voltage. Failure to comply with this instruction may result in personal injury or death.
• If the hybrid/EV battery pack is damaged or overcharged, there is a risk of exposure to hazardous voltage and/or highly corrosive electrolyte mist. If liquid or vapor is observed leaking from the hybrid/EV battery pack, take the following action:
  • Evacuate the area.
  • Notify manager.
  • Do not breathe smoke/vapor.
  • Contain spillage using spill kit.
  • Wash any spillage off body and clothing (remove contaminated clothing).
• If the electric vehicle warning indicator is illuminated, the battery energy control module cannot isolate the high voltage cables. Be aware that live working will be necessary to rectify the fault. Failure to comply with this instruction may result in personal injury or death.
• Be aware that a motor generator can generate a voltage if the wheels are rotated, even if the electric vehicle system has been made safe. Failure to comply with this instruction may result in personal injury or death.
• Wait at least 30 seconds after the engine stops before commencing any repair to the high-pressure fuel injection system. Failure to follow this instruction may result in personal injury
• Before any work is completed on the fuel system, ground the vehicle to earth and maintain the ground connection until the work is complete
• Do not perform any repairs to the high pressure fuel system when the engine is running. The fuel pressure can be extremely high. Failure to follow this instruction may result in personal injury.
• Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapours are always present and may ignite. Failure to follow these instructions may result in personal injury
• After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow these instructions may result in personal injury
• If fuel is taken internally, DO NOT induce vomiting. Seek immediate medical attention. Failure to follow this instruction may result in personal injury.
• If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek medical attention.

  Failure to follow this instruction may result in personal injury.

• Wash hands thoroughly after handling, as prolonged contact may cause irritation. Should irritation develop, seek medical attention. Failure to follow this instruction may result in personal injury.
• This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.

CAUTIONS:

• Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does not guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and /or the donor vehicle.
• It is essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. Failure to follow this instruction may result in damage to the vehicle.
• Make sure that the workshop area in which the vehicle is being worked on is as clean and dust-free as possible. Areas in which work on clutches, brakes or where welding or machining are completed are not suitable in view of the risk of contamination to the fuel system. Failure to follow this instruction may result in damage to the vehicle.
• Make sure that any protective clothing worn is clean and made from lint-free non-flocking material. Failure to follow this instruction may result in damage to the vehicle.
• Make sure that clean, non-plated tools are used. Clean tools using a new brush that will not lose it's bristles and fresh cleaning fluid prior to starting work on the vehicle. Failure to follow this instruction may result in damage to the vehicle.
• Use a steel-topped work bench and cover it with clean, lint-free, non-flocking material. Failure to follow this instruction may result in damage to the vehicle.
• Before disconnecting any part of the system, it is imperative that all dust, dirt and debris is removed from around components to prevent ingress of foreign matter into the fuel system. Failure to follow this instruction may result in damage to the vehicle.

NOTES:

• If a control module or a component is at fault and the vehicle remains under manufacturer warranty, refer to the Warranty Policy and Procedures manual, or determine if any prior approval program is in operation, prior to the installation of a new module/component.
• When performing voltage or resistance tests, always use a digital multimeter accurate to three decimal places, and with an up-to-date calibration certificate. When testing resistance always take the resistance of the digital multimeter leads into account.
• Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
• When measuring fuel sender resistance values with a multimeter, it is critical to use the correct multimeter setting. The multimeter should not be on the 'Auto' setting and must be set to 'Manual'. This will help prevent incorrect diagnosis and unnecessary replacement of fuel senders. If the multimeter range is set at 'Auto' then, during a sweep of the sender from 50 Ohms to 998 Ohms, the multimeter has to change its measurement range. For approximately 1 second, during the range switch over point, the multimeter display indicates an open circuit. This can lead to a mis-diagnosis of a fuel sender fault.

1. Verify the customer concern
2. Visually inspect for obvious signs of damage and system integrity

Visual Inspection

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively check for Diagnostic Trouble Codes (DTCs) and refer to the DTC Index
5. Check the JLR claims submission system for open campaigns. Refer to the corresponding bulletins and SSMs which may be valid for the specific customer complaint and complete the recommendations as required

SYMPTOM CHART

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