Mis-Fueling Issues - Adding Diesel Exhaust Fluid (DEF) To The Diesel Fuel Tank

WARNING: This page is about a different car, the 2018 Land Rover Discovery and 2017 Land Rover Discovery. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

The customer MUST be informed prior to vehicle hand-over of the consequences of adding diesel exhaust fluid to the fuel tank instead of diesel
The cost of this repair work is not Jaguar Land Rover's responsibility. If the customer does not have all of the appropriate work carried out, warranty may be refused on all affected components.
If the customer refuses the advised repair or wants a lower level repair than advised, the vehicle must be added to the Restricted Warranty Register.
Vehicle mis-fuelling will not result in a formal warranty restriction if the approved repair has been completed.
The symptom charts below describe the four possible scenarios of a customer incorrectly fuelling a diesel engine vehicle with diesel exhaust fluid. When customers report a mis-fuel, allow them to fully explain exactly what took place before advising the necessary repair.
The procedures listed below are for guidance only. The relevant sections of TOPIx must be referred to for all detailed procedures and replacement of parts.
Purge operation of the low pressure fuel pumps on the following vehicle lines is activated when the drivers door is opened: Jaguar XE, Jaguar XF, Jaguar F-Pace. For all other vehicle lines, the purge operation of the low pressure fuel pumps is activated when the ignition is switched on.

Mis-fueling Procedure 1

SYMPTOM	POSSIBLE CAUSES	ACTION
Mis-fueling issue. The diesel fuel tank has been filled with diesel exhaust fluid	The vehicle has been incorrectly fueled and the ignition switch has NOT been switched to ON	Referring to the relevant section in the workshop manual, drain the fuel tank Remove the primary fuel pump/sender module and in-tank transfer pipe. Invert the pump/sender module to drain excess fuel Remove all traces of residual fuel within the fuel tank using clean absorbent cloth/paper Flush the pump/sender module and in tank transfer pipe with clean diesel Reassemble the pump/sender module and in tank transfer pipe to the fuel tank and install to the vehicle Fully fill the fuel tank with clean diesel Road test the vehicle for at least 10 miles/16Km Return the vehicle to the customer

Mis-fueling Procedure 2

SYMPTOM	POSSIBLE CAUSES	ACTION
Mis-fueling issue. The diesel fuel tank has been filled with diesel exhaust fluid	The vehicle has been incorrectly fueled and the ignition switch has been switched to the ON position	Referring to the relevant section in the workshop manual, drain the fuel tank Remove the fuel pump module and fuel level sensor Remove all traces of residual fuel within the fuel tank using clean absorbent cloth/paper Invert the fuel pump module and fuel level sensor to remove all traces of residual fuel Remove the fuel filter and discard Disconnect the fuel feed to the high-pressure fuel pump Flush all the fuel lines with clean diesel Reassemble the fuel pump module and fuel level sensor to the fuel tank Install a new fuel filter Fully fill the fuel tank with clean diesel Road test the vehicle for at least 10 miles/16Km, checking for normal engine operation and no stored DTC'S Return the vehicle to the customer

Mis-fueling Procedure 3

SYMPTOM	POSSIBLE CAUSES	ACTION
Mis-fueling issue. The diesel fuel tank has been filled with diesel exhaust fluid	The vehicle has run for less than two minutes	Referring to the relevant section in the workshop manual, drain the fuel tank The residual fuel from all removed parts needs to be checked for metal particles using a magnet Remove the fuel pump module and fuel level sensor Remove all traces of residual fuel within the fuel tank using clean absorbent cloth/paper Invert the fuel pump module and fuel level sensor to remove all traces of residual fuel Remove the fuel filter and discard Disconnect the fuel feed to the high-pressure fuel pump Flush all the fuel lines with clean diesel If no metal particles are detected, go to step 11 If metal particles are present, go to procedure 4 and carry out step 3 to step 8 Reassemble the fuel pump module and fuel level sensor to the fuel tank Install a new fuel filter Fully fill the fuel tank with clean diesel Road test the vehicle for at least 10 miles/16Km, checking for normal engine operation and no DTC'S Return the vehicle to the customer

Mis-fueling Procedure 4

SYMPTOM	POSSIBLE CAUSES	ACTION
Mis-fueling issue. The diesel fuel tank has been filled with diesel exhaust fluid	The vehicle has been driven until it stops or over two minutes. The entire fuel system will need reworking	Referring to the relevant section in the workshop manual, drain the fuel tank Clean and flush all the low pressure fuel pipes Replace the fuel filter Replace the high pressure fuel pump Replace all the high pressure fuel pipes Replace the diverter pipe and both fuel rails Replace the fuel cooler Replace all the fuel injectors Replace the fuel pump module and fuel level sensor Remove all the traces of residual fuel within the fuel tank using clean absorbent cloth/paper Invert the fuel pump module and fuel level sensor to remove all the traces of residual fuel Reassemble the fuel pump module and fuel level sensor to the fuel tank Fully fill the fuel tank with clean diesel Road test the vehicle for at least 10 miles/16Km, checking for normal engine operation and that no stored diagnostic trouble codes are logged Return the vehicle to the customer