NHTSA Recall Query RQ19004

In October 2012, Jaguar Land Rover LLC (JLR) submitted a Defect Information Report (DIR) to NHTSA describing a defect condition that could result in pressurized fuel leaks around the fuel supply line connection on the upper surface of the fuel tank assemblies of approximately 4,152 model year (MY) 2010 Jaguar XF vehicles equipped with 5.0L engines and manufactured between April 2009 and January 2010 (Recall 12V-521). The DIR indicated that the fuel system operating pressures of 5.0L gasoline engine XF vehicles may exceed the design specification under certain conditions, which may result in cracks in the fuel tank outlet flange. In January 2010, JLR changed the design of the tank outlet flange from the original version with no internal ribs, part number 9X23-9A309-AC (?AC flange?), to a revised part with internal ribbing reinforcing the area of the flange at the base of the fuel supply port where the cracks were occurring (?AD flange?). The scope of 12V-521 included 43 MY 2011-2012 XF vehicles with 5.0L engines that were equipped with the AC flanges as service replacement parts. In addition, in March 2016, JLR recalled 28 additional MY 2010 XF vehicles built with 5.0L engines and AC flanges that were inadvertently excluded from 12V-521 (Recall 16V-187). The AD flange was later replaced in production by the AE flange, which had internal ribbing like the AD flange and was used by JLR as the remedy part for 12V-521 and 16V-187. All the subject fuel tank flanges (AC, AD & AE) were supplied to JLR by Continental AG (now Vitesco Technologies). By October 2019, JLR had completed the recall remedies for 12V-521 and 16V-187 in 4,080 vehicles, resulting in an overall completion rate of 97 percent.On June 28, 2019, ODI opened RQ19-004 to investigate the scope and remedy for recalls 12V-521 and 16V-187, based on 30 complaints alleging fuel odor or leakage from the tank flange, including 19 in MY 2010 XF 4.2L vehicles equipped with the AC flange and 11 in MY 2010 through 2012 XF