2011 Land Rover LR4

The Office of Defects Investigation (ODI) opened PE20-018 on November 5th, 2020, to investigate fuel leak allegations in vehicles equipped with fuel tank outlet flange Part Number AH229039AB. ODI based the investigation on six consumer complaints it had received and, using information gathered from RQ19-004, five field reports and 200 warranty claims in the subject vehicles. At the closing date of PE20-018, the number of related complaints received by ODI has risen to fifteen. In response to an ODI Information Request (IR) letter, Land Rover identified: 57 additional warranty claims (257 total), four additional consumer complaints (ten total), and five dealer field reports.Land Rover?s internal investigation identified a cyclic fuel pressure condition that led to cracks forming in the outlet flanges, resulting in fuel leaks. Fuel tank outlet flange revisions to the subject AH229039AB component increased the rigidity of the outlet flange in the area experiencing the highest stress. As Land Rover continued to assess field returned components, they identified cracks in the vicinity of subsurface voids in the subsequent AH229039AC and AH229039AD fuel tank outlet flanges.Based on the information gathered, Land Rover`s Recall Determination Committee (RDC) elected to recall vehicles with the subject fuel outlet flange and expanded the scope to include all vehicles equipped with fuel outlet flange Part Numbers AH229039AA, AH229039AB, AH229039AC, and AH229039AD. Land Rover will replace the previously listed part numbers with an updated designwhich reduces the pressures exerted on the fuel flange. Recall 21V-635 (covering MY2010-2013 Range Rover Sport and MY2010-2016 LR4 vehicles equipped with 3.0L V6 or 5.0L V8 engines) was reported to NHTSA on February 16, 2021. An interim owner notification letter was distributed in October 2021 alerting owners to the defect and the availability of like for like replacements until the remedy parts become available. Land Rover has indicated that remedy parts will become available in the second quarter of 2022. Correspondence from the fuel outlet flange supplier (Vitesco Technologies) indicated that the components at issue in this investigation were sold exclusively to Land Rover.This Preliminary Evaluation has been closed due to the recall issued by the manufacturer (NHTSA Recall 21V-635). The fifteen consumer complaints reports cited above can be reviewed at NHTSA.gov under the following reference numbers: 11122159, 11155570, 11156894, 11220260, 11255901, 11280630, 11337853, 11375884, 11383192, 11388329, 11420940, 11423024, 11428966, 11431744,11440020.

The contact owns a 2011 Land Rover LR4. The contact stated that the vehicle was leaking fuel and there was an abnormal fuel odor coming from the vehicle. The contact later discovered that the VIN was included in NHTSA Campaign Number: 21V635000 (Fuel System, Gasoline); and associated the failure with the recall. The vehicle was taken to the dealer and was repaired under the recall. Upon returning to the dealer, the contact was informed by the service tech that there was a part not properly connected to the fuel tank. The contact waited for an additional half hour before the vehicle was returned. Days later, after refueling the vehicle, fuel started pouring directly from the fuel tank. The vehicle was taken back to dealer, where a service advisor informed the contact that the mechanic had botched the recall repair and that the flange was not properly connected to the fuel tank. After the second repair, the contact stated that while his wife was driving the vehicle, the gas and check engine warning lights illuminated. The contact used a code reader to scan the vehicle and retrieved DTC: P0442-Small EVAP leak. The contact reached out to the dealer and was informed that he had to pay for a diagnostic test to determine the cause of the failure. The manufacturer was notified of the failure. The vehicle was not repaired. The failure mileage was 169,571.

NHTSA ID

11746689

Incident

May 1, 2026

Mileage

169,571 mi

See attached document for complaint.

NHTSA ID

11620448

Incident

Jul 23, 2024

The contact owns a 2011 Land Rover LR4. The contact stated while driving at an undisclosed speed, the vehicle stalled with the low coolant warning light illuminated. The vehicle was taken to an independent mechanic where it was diagnosed and determined that the engine had failed due to coolant intrusion into the engine. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The contact stated while driving at an undisclosed speed to the dealer, the vehicle lost motive power with the low coolant warning light illuminated. The contact was informed that coolant was leaking into the engine and the engine needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 125,000.

NHTSA ID

11613872

Incident

Sep 10, 2024

Mileage

125,000 mi

The contact owns a 2011 Land Rover LR4. The contact stated that while the vehicle was parked, a hotel resident observed condensation leaking from the rear of the vehicle. The vehicle was towed to a dealer where it was diagnosed that the fuel flange assembly needed to be replaced. The contact received notification of Manufacturer Recall Number: N623 The vehicle was repaired, but the failure reoccurred two years later. The manufacturer was notified of the failure. The failure mileage was 152,617.

NHTSA ID

11609483

Incident

Aug 1, 2022

Mileage

152,617 mi

Fuel pouring out from top of fuel tank while vehicle running

NHTSA ID

11543645

Incident

Sep 3, 2023

When I was driving this car, I smelled gasoline very badly, so suddenly the car slammed, and then the car broke down, and there was a lot of white gas or smoke under the hood, I couldn't be sure, so I called The fire alarm was dealt with, then I towed the vehicle to the dealer, contacted my insurance, and the dealer told me there was a recall, but my engine was dead and it wasn't covered by their warranty, but I checked the recall , the reason for the recall may be that the fuel gauge cannot display accurate fuel pressure, which causes the engine to run at high temperature, and the oil cannot cool down, which eventually causes the oil pump body to burst and cause the engine to break down. If I did not contact the fire alarm, this would be a serious event. Fire is even a direct safety accident in driving. I request to report the accident and ask the dealer to bear the repair costs and all losses caused by the accident damage.

NHTSA ID

11513959

Incident

Feb 28, 2023

The contact owned a 2011 Land Rover LR4. The contact stated while driving at 35 MPH, the vehicle accelerated independently and the brake pedal was depressed in order to regain control. The vehicle was taken to a certified mechanic who was unable to diagnose the failure. On a separate occasion, the contact stated that while driving approximately at 3 MPH into a parking garage, the vehicle accelerated independently and the brake pedal was depressed with force however it went through the wall of the garage and into the home where it came to a stop after crashing into a generator. The vehicle was towed and deemed totaled. The air bags did deploy. There were no injuries reported. The garage was damaged. A police report was filed. The manufacturer was not made aware of the failure. The approximate failure mileage was 36,000.

NHTSA ID

11505759

Incident

Mar 6, 2022

Mileage

36,000 mi

Fuel smell lead to fuel leaking

NHTSA ID

11483270

Incident

Sep 1, 2022

RESCINDED - Windshield Wiper Noise / Judder / Streak - RESCINDED

Damage/marking may be evident on the surface of the Instrument Cluster (IPC) lens.

The front and/or rear parking aid system may be inoperative.

PCV DiaphramTorn. The Check Engine Lamp is illuminated.

Damage/marking may be evident on the surface of the IPC (Instrument Cluster) lens.

A humming noise may be evident from the engine at idle.