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Jaguar Defect Investigation RQ19004: Fuel Tank Fuel Outlet Flange Leak
2011 Jaguar XF
Fuel Tank Fuel Outlet Flange Leak
Fuel System, Gasoline:Delivery:Fuel Pump
- In 2012 and 2016, Jaguar conducted recalls 12V-521 and 16V-187 (subject recalls) to address a defect condition involving leakage from cracked fuel tank fuel outlet flanges in certain model year (MY) 2010 through 2012 Jaguar XF vehicles equipped with 5.0L gasoline engines. The recalled vehicles were manufactured from December 2008 through January 2010, or had a subject fuel outlet flange fitted as service replacement part. Jaguar's description of the defect condition indicated that, if a crack is present in the fuel outlet flange, drivers may smell fuel odor and in some circumstances with the vehicle static, there could be liquid fuel underneath the rear of the vehicle, which in the presence of an ignition source could lead to a fire.The subject Jaguar XF vehicles were available with either 4.2L or 5.0L engines in MY 2010. The MY 2011 and 2012 XF vehicles are all equipped with 5.0L engines. The subject vehicles have a returnless fuel system with a fuel filter integrated in the fuel outlet flange. The flange cracks appear to occur in a high-stress region near the center of the filter cartridge dome that surrounds the base of the fuel outlet port (this area is subjected to fuel pump discharge pressure). Jaguar limited the recall to the 5.0L XF vehicles based on its assessment of field data in 2012 and because the greater fuel system operating pressures for those engines were found to produce greater stresses in the critical region of the outlet flange.The recalled fuel outlet flange was introduced at the start of production for MY 2010 XF vehicles in December 2008 (P/N 9X23-9A309-AA/AD). In January 2010, a redesigned fuel outlet flange with enhanced internal reinforcement of the fuel filter cartridge dome was implemented as a running change in vehicle production (P/N 9X23-9A309-AE). The remedies for the subject recalls required replacement of the fuel outlet flange with the redesigned part. A further redesign of the fuel outlet flange, with external reinforcement of the filter cartridge dome, was implemented at the start of MY 2013 production (P/N DX23-9A309-AA). The fuel flange assemblies are made of a Nylacast Polyacetal material (POM-C) and supplied by Continental Teves.The Office of Defects Investigation (ODI) has received 30 unique VIN complaints alleging fuel odor and/or leaks from the rear passenger side of the vehicle occurring in MY 2010 4.2L XF vehicles (19) or in MY 2010 through 2012 5.0L XF vehicles (11). The 4.2L XF complaints are believed to all involve the original flange design that was recalled for the 5.0L XF vehicles. The 5.0L XF complaints involve vehicles equipped with the redesigned/remedy part, either as original equipment or from replacement under the subject recalls. A Recall Query has been opened to assess the scope and remedy of the subject recalls.The following VOQ numbers are associated with this opening resume: 11197034, 11193073, 11152571, 11149589, 11149472, 11145319, 11142957, 11133362, 11118866, 11114463, 11104523, 11055587, 11040621, 11006172, 11000867, 10995536, 10934750, 10930054, 10920567, 10916210, 10908138, 10905741, 10897059, 10887524, 10884786, 10822314, 10789474, 10745695, 10661562, 10659664, 10627191.
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