2011 sd4 hse,
filled up tank, 80mls later gauge drops to less than half, range to 170, topped up again, took next to nothing,would be greatfull for ideas,.

This has been covered a few times, basically it poor connections on the fuel tank.

http://www.freel2.com/forum/topic12990.htm...;start=120

TECHNICAL_BULLETIN_LTB00566v6

Below is the text of the bulletin, but it doesn't include the photos and other formatting - I'll keep trying to find a way of doing that..............
But it's readily available on a Google search, so can't be that confidential; https://www.google.co.uk/search?q=LTB00566...p;ie=UTF-8
-------------------------------------------------------------------------------------------
TECHNICAL BULLETIN
LTB00566v6
04 JUL 2014
________________________________________
© Jaguar Land Rover Limited
All rights reserved.
This reissue replaces all previous versions. Please destroy all previous versions.
This bulletin supersedes TSB LTB00566v5/2014 dated 03 APR 2014, which should either be destroyed or clearly marked to show it is no longer valid (e.g. with a line across the page). Only refer to the electronic version of this Technical Bulletin in TOPIx.
Changes are highlighted in gray
SECTION: 310-00
Fuel Gauge Operation Not Accurate
AFFECTED VEHICLE RANGE:
Freelander 2/LR2 (LF)
Model Year: 2007-2012
VIN: 7H000634-CH292666

Discovery 4 / LR4 (LA)
Model Year: 2010-2013
VIN: AA510178-DA656034

Range Rover (LM)
Model Year: 2010-2012
VIN: AA304426-CA369495

Range Rover Sport (LS)
Model Year: 2010-2013
VIN: AA212145-DA790997

MARKETS:
All
CONDITION SUMMARY:
Situation:
A customer complaint of the fuel gauge not working or the gauge is not accurate.
Please advise the customer, if possible, to bring the vehicle in with the fuel tank level below 1/4 full.
This Version has been issued for a change to the Service Instruction.
Cause: Fretting corrosion across the fuel level sender harness pins inside the fuel tank. Suggested Customer Concern Code - L69.
Action: After completing primary diagnostics and where the cause is not identified, follow the Service Instruction below. Any issues found during the primary diagnostics must be carried out as a separate warranty claim.
PARTS:
CAUTION: The splices listed below are specific to this repair. Make sure that these splices are used and crimped using special tool 418-116A (YRW500010).
LR050538 Splice joint connector Quantity: 6
ESR3806 Fuel tank flange o-ring seal (Range Rover) Quantity: 2
LR000966 Fuel tank flange o-ring seal (Except Range Rover) Quantity: 1
WARRANTY:
Freelander 2 Diesel up to VIN H281016 only:
Pin Numbers Lower Resistance Value (Ohms) Upper Resistance Value (Ohms)
Check 1 1 2 46.2 1002.2
Check 2 5 6 46.2 1002.2
All models except: Freelander 2 Diesel up to VIN H281016
Pin Numbers Lower Resistance Value (Ohms) Upper Resistance Value (Ohms)
Check 1 1 2 46.2 1002.2
Check 2 1 6 46.2 1002.2
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 - All except Freelander 2/LR2 88.25.89/35 1.5 X2 LR042971/LR042716/LR043153
Fuel sender harness modification - Freelander 2/LR2 2WD 88.25.89/35 2.1 X2 LR036125
Fuel sender harness modification - Freelander 2/LR2 3.2L Gasoline 88.25.89/35 2.6 X2 LR038723
Fuel sender harness modification - Freelander 2/LR2 All except 3.2L Gasoline and 2WD 88.25.89/35 2.4 X2 LR036125
NOTE: Normal Warranty procedures apply.
SERVICE INSTRUCTION:
CAUTION: Inspect the fuel tank flange electrical connector for damaged or backed out pins before removing the fuel tank flange. Any repair carried out to the fuel tank flange electrical connector should be carried out as a separate warranty claim.
1. Remove the fuel pump and sender unit (see TOPIx workshop manual, section 310-01).
2. Place the fuel pump and sender unit/fuel pump module on a clean work surface.
CAUTION: To reduce the chance of incorrect wiring of the harnesses, wherever possible, only repair one wire at a time.
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 3 in total) as possible.
NOTE: Some variation in the illustrations may occur, but the essential information is always correct.
3. 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.
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.
When installing the splices, make sure that the splice is crimped in the correct location.
1. Correct location for crimping.
2. Incorrect location for crimping.
4. Identify the connector to be removed.
• Cut the wires shown as close to the connector as possible.
5. Using a suitable tool, remove 5mm of insulation from the end of the 2 wires.
6. 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.
Install a splice to the ends of the wires, and crimp both ends using a special tool 418-116A.
7. Repeat steps 4 to 6 to the other wire.
• Discard the connector.
8. Using a suitable tie strap, secure the two splices together.
9. Identify the earth connector (two black wires) to be removed.
• Cut the wires shown as close to the connector as possible.
• Discard the connector.
10. NOTE: The two splices are not connected until step 14.
Install a splice to the end of each wire.
• Using a suitable tool, remove 5mm of insulation from the end of the 2 wires.
• Crimp the splices using special tool 418-116A.
11. CAUTION: Do not install the fuel tank flange at this point.
Install the fuel pump sender unit to the fuel tank (see TOPIx Workshop Manual, section 310-01).
12. CAUTION: Make sure that the correct wires are re-connected to each other.
Identify the connector to be removed.
• Carefully withdraw the connector out of the tank.
• Cut the wires shown as close to the connector as possible.
• Discard the connector.
13. 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.
Install a splice to the ends of the wires, and crimp both ends using special tool 418-116A.
• Using a suitable tool, remove 5mm of insulation from the end of the wires.
• Crimp the splices using special tool 418-116A.
• Using a suitable tie strap, secure the two splices together.
14. 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.
If equipped, connect the two earth wires from the base of the fuel tank flange to the two splices installed in step 10.
• Position the fuel tank flange close to the fuel tank.
• Using a suitable tool, remove 5mm of insulation from the end of the two wires.
• Crimp the splices using special tool 418-116A.
• Using a suitable tie strap, secure the two splices together.
15. Using a suitable tool, check the resistance values across fuel tank flange pins listed in the table above.
1. If the resistance value is between 46.2 and 1002.2 ohms, continue to step 16.
2. If the resistance value is outside this range, further investigation is required.
16. CAUTION: Make sure that a successful resistance check has been carried out before continuing to install the fuel pump sender unit.
Carry out the remaining steps of the fuel pump and sender unit/fuel pump module procedure (see TOPIx Workshop Manual, section 310-01).
17. If required, using Land Rover approved diagnostic equipment read and clear any stored DTCs. FL2 XS SD4 Auto 2010 2012-2017 (21k - 91k miles) (MY2011)
FL2 Metropolis SD4 Auto 2014 2017- (16k - 82k+ miles) (MY2015)
Metro in its 11th Year of (Extended) LR Warranty / Full LR Service History
(Expensive, but Trouble/Worry free - hopefully?)

Excellent. Many thanks IanMetro.
I'm sure I've looked at that before - at least a year or so ago, thinking I was glad this hadn't happened to me. Famous last words and all that.

Here are the images to go with the directions

Hello - Thank you for posting the excellent breakdown. My Freelander 2 2007 has developed this problem. I am looking into doing the fix. A replacement fuel sender gasket LR000966 > LR117476 seems advisable alongside also replacing the propshaft bolts. Crimping the wires and what to use to do this is something I am not sure on. The bulletin mentions to use special tool 418-116A. Can anybody kindly recommend suitable crimps crimpers and sleeves to use? Many thanks

I've got a couple of the genuine LR crimp connectors left from when I had mine done. I bought 6 after reading the bulletin and the FL2 only needs 2

They're kicking about in my garage somewhere...

If you can give me a few days to dig them out and pm me your address, I'll pop a couple in the post to you...

Can heat shrink be used in the area or is it not recommended ? i wonder how many have undertaken this solution up to date.

NeilTD4 wrote:

I've got a couple of the genuine LR crimp connectors left from when I had mine done. I bought 6 after reading the bulletin and the FL2 only needs 2

They're kicking about in my garage somewhere...

If you can give me a few days to dig them out and pm me your address, I'll pop a couple in the post to you...

Thank you for your very kind offer, I am also now checking what my local garage would charge and will come back if I persue a diy route. many thanks again

Nerrad65 wrote:

Hello - Thank you for posting the excellent breakdown. My Freelander 2 2007 has developed this problem. I am looking into doing the fix. A replacement fuel sender gasket LR000966 > LR117476 seems advisable alongside also replacing the propshaft bolts. Crimping the wires and what to use to do this is something I am not sure on. The bulletin mentions to use special tool 418-116A. Can anybody kindly recommend suitable crimps crimpers and sleeves to use? Many thanks

Ah ... I did wonder about the "specialist tool" mentioned in T bulletin so that's allayed my fears of having to source an expensive LR tool and really helpful, thank you!

I got my local trusted garage to do mine, but I provided the genuine LR and the new big O ring...

I did have a look for the spare crimps over the weekend, but no luck so far...

Update on my fuel guage issue. I decided in the end to take my FRL2 to my local garage for diagnosis. The result for plug in diagnostics gave no fault codes & activate fuel guage via diagnostics all reading ok. They then checked connection on top of the sender unit to find 2 pins slightly open which they "closed up as required and cleaned connection". I am currently monitoring but it seems the problem is solved. I took the FRL2 on an extended trip over the weekend, ran the guage to nearly empty and topped up, sofar seems issue is fixed ... which is a nice surprise ...... also helped my youngest move house, did you know you can fit a two seater sofa in the back of a FRL2 ..... ok carefully tying the door closed, but still not that many vehicles you can do that with