Recall N623 Fuel Tank Leak – 2010-2013 Land Rover Range Rover Sport & 2010-2016 LR4

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August 12, 2021 NHTSA CAMPAIGN NUMBER: 21V635000

Fuel Outlet Flange May Crack And Leak Fuel

A fuel leak in the presence of an ignition source increases the risk of a fire.

 

NHTSA Campaign Number: 21V635

Manufacturer Jaguar Land Rover North America, LLC

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 111,746

 

Summary

Jaguar Land Rover North America, LLC (Land Rover) is recalling certain 2010-2013 Range Rover Sport and 2010-2016 LR4 vehicles equipped with 3.0L V6 or 5.0L V8 engines. The fuel outlet flange mounted on the fuel tank may crack, possibly resulting in a fuel leak.

 

Remedy

Dealers will replace the fuel outlet flange, free of charge. Interim owner notification letters were mailed October 7, 2021. The remedy is expected to be available April 30, 2022. Owners may contact Land Rover customer service at 1-800-637-6837. Land Rover’s number for this recall is N623.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Land Rover has a Recall

 


573.6 (c) (6) – Chronology of Events (Recall N623)

 

NHTSA raised a Recall Query (RQ) investigation RQ19-004 concerning Jaguar XF 4.2L vehicles and reports of fuel leaks from the fuel tank outlet flange.  Reflecting on the response to NHTSA, Product Safety and Compliance Committee (PSCC) investigation was opened on February 16, 2021.

 

In April 2021, NHTSA requested Jaguar Land Rover investigate and respond to their Preliminary Evaluation PE20-018 concerning LR4 and Range Rover Sport fuel tank outlet flanges.

 

Jaguar Land Rover investigated and provided a response to NHTSA during June 2021 but, prompted by NHTSA’s enquiry and following reviews of field data also opened an internal investigation

 

The internal investigation conducted by the PSCC requested a review by engineering into the possible causes of the issue and subject parts to be returned from the market so engineering could identify the origin of the leak and scope of vehicles affected.

 

A detailed technical review of the fuel system, engine management system interaction with the fuel system, fuel pump operating strategy and fuel tank outlet design changes and validation of designs was conducted as part of the internal investigation. This was routinely reviewed by the PSCC through March, April, May, June and July 2021.

 

Field return parts were also inspected as part of this internal investigation to understand the failure mechanism and contributory factors. This revealed the presence of cracks around sub-surface voids in the fuel tank outlet flange. The cracks would propagate over time and with the flexing of the outlet flange due to the integrated fuel filter which pulsates as fuel pressure rises and falls, become sufficiently large to allow liquid fuel to leak out.

 

The PSCC reviewed all the information available on August 3, 2021, and concluded that the issue should be progressed to the Jaguar Land Rover Recall Determination Committee (RDC).

 

The RDC review commenced on August 5, 2021, and characterized this concern as a safety defect as it is possible that fuel vapor or liquid fuel may ignite if it comes into contact with an ignition source. The decision was made by the RDC to voluntarily recall all affected vehicles.

There have been no reported accidents, injuries or fires as a result of this concern.

 

Jaguar Land Rover used 687 Warranty Claims, Field Reports, and Customer complaints from January 21, 2011, to February 2, 2021, in determining the nature of the issue.

 


 


11 Affected Products

Vehicles

MAKE MODEL YEAR
LAND ROVER LR4 2010-2016
LAND ROVER RANGE ROVER SPORT 2010-2013

 


26 Associated Documents

Miscellaneous Document – Campaign Launch Status – N623 SAFETY RECALL RR SPORT & LR4 FUEL TANK LEAK

RMISC-21V635-8740.pdf 71.667KB

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Updated Chronology

RMISC-21V635-6106.pdf 62.604KB

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Chronology

RMISC-21V635-3774.pdf 61.956KB

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Manufacturer Notices(to Dealers,etc) – NOTIFICATION OF SAFETY RECALL N623

RCMN-21V635-0337.pdf 63.508KB

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N623 SAFETY RECALL RR SPORT & LR4 FUEL TANK LEAK

RMISC-21V635-9021.pdf 54.241KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V635-5503.pdf 274.2KB

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N623 SAFETY RECALL RR SPORT & LR4 FUEL TANK LEAK

RMISC-21V635-0754.pdf 53.944KB

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SAFETY RECALL N623 & ONP H380/N636

RMISC-21V635-7698.pdf 74.527KB

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21V635 Q&A

RMISC-21V635-7310.pdf 159.251KB

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21V635 Q&A

RMISC-21V635-8072.pdf 150.938KB

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Campaign Launch Status: Safety Recall N623, RR Sport & LR4 Fuel Tank Leak

RMISC-21V635-4382.pdf 89.617KB

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N623 SAFETY RECALL RR SPORT & LR4 FUEL TANK LEAK

RMISC-21V635-1866.pdf 75.002KB

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N623 SAFETY RECALL RR SPORT & LR4 FUEL TANK LEAK

RMISC-21V635-1646.pdf 54.25KB

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AFETY RECALL N623 -FUEL LEAKING FROM TANK OUTLET PIPE FLANGE

RMISC-21V635-3793.pdf 80.349KB

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Recall 573 Report – AMENDMENT 2

RCLRPT-21V635-9087.PDF 214.657KB

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Recall 573 Report – AMENDMENT 3

RCLRPT-21V635-9466.PDF 214.661KB

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Recall 573 Report – AMENDMENT 1

RCLRPT-21V635-6663.PDF 214.658KB

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Recall Acknowledgement

RCAK-21V635-1841.pdf 688.65KB

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Defect Notice 573 Report

RCLRPT-21V635-1019.PDF 214.658KB

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Campaign Launch Status -SAFETY RECALL N623 – FUEL LEAKING FROM TANK OUTLET PIPE FLANGE & EMISSION RECALLS – N622 and H374 SECONDARY FUELING ADAPTIONS

RMISC-21V635-0692.pdf 74.921KB

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N623 SAFETY RECALL – RR SPORT & LR4 FUEL TANK LEAK

RMISC-21V635-9252.pdf 54.854KB

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N623 SAFETY RECALL – RR SPORT & LR4 FUEL TANK LEAK

RMISC-21V635-5720.pdf 80.482KB

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SAFETY RECALL N623 – FUEL LEAKING FROM TANK OUTLET PIPE FLANGE

RMISC-21V635-1691.pdf 49.02KB

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Campaign Launch Status: N654 – FRONT SEAT AIRBAGS & N623 FUEL TANK FLANGE

RMISC-21V635-0399.pdf 75.54KB

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Campaign Launch Status: SAFETY RECALL N623 – FUEL LEAKING FROM TANK OUTLET PIPE FLANGE

RMISC-21V635-8708.pdf 48.333KB

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Manufacturer Notices(to Dealers,etc) – Technical Service Bulletin

RCMN-21V635-3815.pdf 723.235KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V635&docType=RCL

 


1 Associated Investigation

Fuel Tank Flange Leak
NHTSA ID: PE20018
Dated opened: November 5, 2020

The subject vehicles are model year (MY) 2010 through 2011 Land Rover LR4 (L319) and Range Rover Sport (L320) vehicles equipped with fuel tank flange part number AH229039AB. The Office of Defects Investigation (ODI) has received six consumer complaints (VOQs) alleging fuel leakage from cracked tank flanges in the subject vehicles. In addition, ODI identified 5 field reports and 200 warranty claims related to the alleged defect in the subject vehicles as part of the peer vehicle field data analysis in Recall Query RQ19-004 regarding tank flange leaks in MY 2010 through 2012 Jaguar XF vehicles. In 2013 Jaguar Land Rover LLC (JLR) submitted a foreign recall report related to the alleged defect in the subject vehicles (Foreign Recall 13F-098). The foreign recall was conducted in eight Middle East countries (Bahrain, Kuwait, Lebanon, Oman, Qatar, Saudi Arabia, United Arab Emirates, and Yemen).

In response to ODI’s information request letter for RQ19-004, JLR indicated that a modified fuel tank flange was implemented as a running change in MY 2011 production of the subject vehicles. Internal ribbing was added to the modified flanges, which increased the strength and creep resistance of the parts in the areas were cracking had been observed. Tank flanges with internal ribbing are identified by part numbers AH229039AC and AH229039AD. The modified flanges were used in approximately 27,882 MY 2011 through 2015 LR4 vehicles and 32,822 MY 2011 through 2013 Range Rover Sport vehicles (peer vehicles). A Preliminary Evaluation has been opened to assess the failure rate and severity of the fuel tank flange cracking condition in subject and peer vehicles sold in the United States.

The following VOQ numbers are associated with this opening resume: 11280630, 11220260, 11155570, 11139276, 11132102, 11098107.


 

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