How-to DIY: Upgrade to new style fuel tank flange & filter

Disclaimer: Links on this page pointing to Amazon, eBay and other sites may include affiliate code. If you click them and make a purchase, we may earn a small commission.

gsxr

Full Access Member
Joined
May 8, 2017
Posts
778
Reaction score
367
Location
Big Sky Country
Most LR4 owners are aware of the TSB RCRIT-21V635-5779 from early 2022, for "Gasoline Fuel Tank Flange Assembly Cracking". The full PDF is at this link. What's not clear in the TSB is what the new parts look like. There have been some threads in the past (like this one) discussing confusion about what is, or is not, included as part of the TSB.

I recently had to replace my fuel pump (entire saga here), and I had not yet had this TSB performed, I opted to do it myself. There is no Land Rover dealer in Montana, and it's a 10 hour drive each way to the dealer in Boise. I'm not aware of any indy shops nearby that I'd trust to do the work correctly. Since I had to drop the tank to replace the fuel pump, I figured I might as well upgrade to the new parts specified by the TSB. No point re-installing a defective part after removing it, right?

Part list from the TSB:

LR112785 - Fuel tank flange assembly (new, updated flange) - $60 MSRP​
LR175172 - Fuel filter (new style filter, requires bracket below) - $88 MSRP​
LR113338 - Bracket for fuel filter (required to mount filter above) - $19 MSRP​
LR117476 - Fuel tank flange O-ring (recommended to replace) - $13 MSRP​
CN100509 - Hose clamp for fuel tank inlet pipe - $2 MSRP​

I ordered the 5 parts above from OEM Parts Online, the order was fulfilled by JLR South Bay in Torrance CA. Total cost was ~$170 including shipping.

To replace these items yourself, you must remove the fuel tank from the truck. Click here for a thread which documents tank removal.

Once the tank is out, follow the steps in this thread to remove the existing, integrated flange+filter assembly (this is the defective item that you will be replacing). You DO NOT need to remove the fuel pump, however if your truck has 150kmi or more and is still on the original pump... consider proactive replacement. My original pump failed at 160kmi. Details about the new OEM VDO pump are in that same thread.

I neglected to take pictures of the old + new flange side by side, ooops.

Here are the first pictures, of the new style flange (without filter), and the new O-ring. The new O-ring is red, the original was green, I assume the change in color indicates a different material. The old O-ring appeared reusable but I didn't want to gamble to save $13.
 

Attachments

  • seal_LR117476.jpg
    seal_LR117476.jpg
    178.5 KB · Views: 16
  • flange_LR112785_4.jpg
    flange_LR112785_4.jpg
    103.9 KB · Views: 22
  • flange_LR112785_3.jpg
    flange_LR112785_3.jpg
    137.4 KB · Views: 22
  • flange_LR112785_2.jpg
    flange_LR112785_2.jpg
    134.8 KB · Views: 22
  • flange_LR112785_1.jpg
    flange_LR112785_1.jpg
    122.3 KB · Views: 16
Last edited:

gsxr

Full Access Member
Joined
May 8, 2017
Posts
778
Reaction score
367
Location
Big Sky Country
Here are photos of the new, separate filter. There are attached flexible pipes which connect between the pump and new-style flange.
 

Attachments

  • filter_LR175172_1.jpg
    filter_LR175172_1.jpg
    116.8 KB · Views: 19
  • filter_LR175172_2.jpg
    filter_LR175172_2.jpg
    139.6 KB · Views: 19
  • filter_LR175172_4.jpg
    filter_LR175172_4.jpg
    140.8 KB · Views: 20
  • filter_LR175172_5.jpg
    filter_LR175172_5.jpg
    88.8 KB · Views: 20
  • filter_LR175172_6.jpg
    filter_LR175172_6.jpg
    170.7 KB · Views: 18

gsxr

Full Access Member
Joined
May 8, 2017
Posts
778
Reaction score
367
Location
Big Sky Country
The new filter has to attach to something, since it's no longer mounted directly to the flange like the old one. This plastic bracket is what the new filter connects to. The filter is a TIGHT fit into the bracket. It will click into place when seated.

The bracket+filter assembly snaps forward into the tank internals. There's a locking tang that will audibly click when seated. This is tricky, you can't see much of anything through the opening in the top of the tank. The pictures in the TSB are marginally helpful. It can only fit one way.

Photos below show the bracket only, before the filter is attached.
 

Attachments

  • bracket_LR113338_1.jpg
    bracket_LR113338_1.jpg
    114.1 KB · Views: 19
  • bracket_LR113338_2.jpg
    bracket_LR113338_2.jpg
    108.2 KB · Views: 17
  • bracket_LR113338_3.jpg
    bracket_LR113338_3.jpg
    107.3 KB · Views: 20
  • bracket_LR113338_4.jpg
    bracket_LR113338_4.jpg
    119.8 KB · Views: 18
  • bracket_LR113338_6.jpg
    bracket_LR113338_6.jpg
    114.8 KB · Views: 17

gsxr

Full Access Member
Joined
May 8, 2017
Posts
778
Reaction score
367
Location
Big Sky Country
First photo below shows the new filter inserted into the bracket, ready for installation into the tank.

Second photo shows the filter+bracket installed in the tank.

Third shows the new flange partially installed.

Fourth photo shows the new flange in place and lock ring installed.

Last photo shows the new hose clamp for the tank filler pipe. The original clamps have tamper seals which are difficult to remove, it's easier to just toss the old clamp and replace it with a new one for two bucks. There are 2 clamps, normally you only need to remove one. However, it won't hurt to have 2 new clamps on hand just in case. They are good quality, Norma-brand clamps, made in Germany.
 

Attachments

  • filter_new1.jpg
    filter_new1.jpg
    145.9 KB · Views: 22
  • filter_new2.jpg
    filter_new2.jpg
    124.9 KB · Views: 20
  • flange_new1.jpg
    flange_new1.jpg
    156.6 KB · Views: 16
  • flange_new2.jpg
    flange_new2.jpg
    181.5 KB · Views: 21
  • clamp_CN100509.jpg
    clamp_CN100509.jpg
    85.1 KB · Views: 21

gsxr

Full Access Member
Joined
May 8, 2017
Posts
778
Reaction score
367
Location
Big Sky Country
Here are photos of the OLD, ORIGINAL, DEFECTIVE DESIGN fuel tank flange with integrated filter. This is what I removed from my tank after 12 years / 160kmi, thankfully it had not yet started leaking.

This part number appears to still be available new, although I don't know why anyone would want to knowingly install a part that could crack and leak fuel. Oddly, it appears even JLR still sells this part! It's $159 MSRP, which is almost as much as the 3 new / updated parts that replace it. I'd have thought JLR would have scrapped existing inventory of the old stuff, and would only sell the new stuff. (???)

Photos courtesy of British Parts of Utah, where I purchased my new OEM VDO fuel pump. This is the OEM VDO part, not OE/Genuine JLR, but OEM and OE are identical other than the label.
 

Attachments

  • LR043420-2.jpeg
    LR043420-2.jpeg
    77.9 KB · Views: 18
  • LR043420-3.jpeg
    LR043420-3.jpeg
    59.2 KB · Views: 17
  • LR043420-4.jpeg
    LR043420-4.jpeg
    75.1 KB · Views: 18

LB Bill

Full Access Member
Joined
Jul 24, 2019
Posts
215
Reaction score
101
Location
California
That's a shock that they might still be selling that old 'recalled' part design. Seems irresponsible and loaded with liability. Thanks for posting. Mine was done by the JLR dealer, and it seems all good. I didn't realize that the flange and filter are now separate parts.
 

lmwong

Member
Joined
Dec 23, 2014
Posts
22
Reaction score
5
Had this recall done at the dealer and as I was pulling away from the dealer, I got a check engine light and restricted performance warning. It seemed to drive fine. They read the code and said there was a camshaft timing error. They’re keeping it over night but said it’s not related to the recall work but a coincidence. Not sure I buy that. Car was running great before I dropped it off. Any thoughts?
 

ugmw177

Full Access Member
Joined
May 25, 2023
Posts
96
Reaction score
60
Location
Charlotte NC
definately a coincidence. i you pulled away quickly on a cold engine, especially with some timing chain slack, the oil pressure in the tensioners had not had time to pressurize the tensioner and "tighten" the chain thus giving the cam timing error. I would listen carefully for a while for timing chain rattles.
 

lmwong

Member
Joined
Dec 23, 2014
Posts
22
Reaction score
5
definately a coincidence. i you pulled away quickly on a cold engine, especially with some timing chain slack, the oil pressure in the tensioners had not had time to pressurize the tensioner and "tighten" the chain thus giving the cam timing error. I would listen carefully for a while for timing chain rattles.
Thank you for this answer.

And apologies for hijacking the thread. Back to gas flange recall parts…I wish were my only problem!
 
Last edited:

Latest posts

Members online

Forum statistics

Threads
36,626
Posts
221,831
Members
30,791
Latest member
Jimrobb
Top