Range Rover Classic Fuel Tank Replacement
RANGE ROVER CLASSIC (LH) FUEL TANK REPLACEMENT1. Drain the gas tank as follows:
^ Disconnect the battery ground cable.
^ Open fuel filler flap and remove cap.
^ If fuel tank is between three quarters full and full, use a fuel recovery system down the filler neck to drain excess fuel until a level below the height of the fuel pump is obtained.
^ Open tailgate.
^ Remove lower tailgate release handle trim. (Figure 1)
^ Remove four fasteners securing load-space carpet to lower tailgate. (Arrowed in Figure 2)
^ Release and fold load-space carpet back for access.
^ Remove sound insulation to reveal fuel pump access panel.
^ Remove fuel pump access panel. (Figure 3)
^ Disconnect connector from fuel pump tank unit.
(Arrowed in Figure 4)
^ Remove sealant and disconnect earth lead from fuel pump tank unit. (Figure 5)
^ Position absorbent cloth around fuel pump unions to protect against fuel spray.
WARNING:
Fuel pressure of up to 2.5 bar will be present in the system, even if the engine has not been run for some time.
WARNING:
The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.
CAUTION:
To prevent damage to components, two open-end wrenches must be used to loosen or tighten unions.
CAUTION:
Always install plugs to open connections to prevent contamination.
^ Disconnect fuel line unions from fuel pump. (Figure 6)
^ Remove absorbent cloth.
^ Using LRT-19-001 remove locking ring securing fuel pump tank unit assembly to fuel tank. (Figure 7)
^ Carefully release fuel pump tank unit assembly. Remove and discard seal.
NOTE:
Always follow the manufacturer's instructions for the connection and safe use of the fuel recovery appliance.
^ Using a fuel recovery system, drain the remaining fuel from the tank into a sealed container.
2. Remove the gas tank as follows:
^ Raise vehicle on lift.
^ Remove and discard tie strap securing evaporative control pipe to fuel tank filler hose.
NOTE:
The forked end of LRT-19-002 must be used to disconnect the "speedfit" connector on the evaporative control pipe.
^ Insert special tool LRT-19-002, press down on collet and simultaneously pull pipe from connector to disconnect evaporative control pipe at green end of speedfit connector. (Figure 8)
^ Disconnect fuel tank vent hose. (Figure 9)
^ Disconnect fuel tank filler hose from fuel tank filler neck. (Figure 10).
^ Remove nut and bolt securing right-hand side fuel tank strap. (Figure 11)
^ Remove rear towing eyes. (Figure 12)
^ Remove rear anti-roll bar bracket securing nuts and bolts.
^ Allow bar to swing down clear of fuel tank. (Figure 13)
^ Remove back two bolts and nut plates securing fuel tank cradle. (Figure 14).
NOTE:
Assistance will be required to support the fuel tank during removal.
^ Remove front nuts, bolts, and washers. Remove the fuel tank cradle.
^ With assistance, lower and remove fuel tank assembly from vehicle.
3. Install the new fuel tank as follows:
NOTE:
Assistance will be required to support the fuel tank during installation.
^ Raise the new fuel tank into position.
^ Position fuel tank cradle to vehicle, install bolts and tighten to 45 Nm (33 lbf.ft).
^ Install back two bolts and nut plates securing fuel tank cradle and tighten to 45 Nm (33 lbf.ft).
^ Position rear anti-roll bar brackets and install securing nuts and bolts.
^ Install rear towing eyes.
^ Install nut and bolt securing right-hand side fuel tank strap.
^ Connect fuel tank filler hose to fuel tank filler neck.
CAUTION:
Fuel vent hoses/pipes must be routed correctly and not restricted.
^ Connect fuel tank vent hose.
^ Ensure fuel vent hoses/pipes are routed correctly and are not restricted.
^ Connect evaporative control pipe at green end of speedfit connector.
^ Install tie strap securing evaporative control pipe to fuel tank filler hose.
4. Install the fuel pump as follows:
^ Lower the vehicle for access.
^ Clean area surrounding fuel tank access.
NOTE:
A new seal must be used.
^ Install new fuel pump tank unit assembly seal to fuel tank.
^ Install fuel pump tank unit assembly to fuel tank.
^ Use LRT-19-001 to tighten locking ring to 47 Nm (34.7 lbf.ft).
^ Remove plugs from open connections.
^ Connect fuel line unions to fuel pump.
^ Connect ground lead to fuel pump tank unit and apply sealant.
^ Install fuel pump tank unit connector.
^ Install fuel pump access panel and secure with screws.
^ Install sound insulation.
^ Reposition load-space carpet.
^ Install four fasteners securing load-space carpet to lower tailgate.
^ Install lower tailgate release handle finisher.
^ Close tailgate.
^ Refill fuel tank with extracted fuel.
^ Install fuel filler cap and check for correct seating. Close fuel filler flap.
^ Connect the battery ground cable.
NOTE:
Campaign labels are no longer required for Safety Recall Campaigns.
5. When all repair work is complete, claim campaign code B156 and correct Option code.