Discovery Fuel Tank Replacement
DISCOVERY (LJ) FUEL TANK REPLACEMENT1. If a rear step is installed on the vehicle, remove the step as follows:
^ Support the step assembly.
^ Remove bolt securing step to chassis, collect the nut and washer.
^ Remove nut securing damper to the step assembly and collect washer.
^ Release damper.
^ With assistance, remove the step assembly.
2. Drain the fuel tank as follows:
^ Disconnect battery ground cable.
^ Open fuel filler flap and remove cap.
^ If fuel tank is between three quarters full and full, connect a fuel recovery system down the fuel filler neck and drain excess fuel until a level below the height of fuel pump is obtained.
^ Open tailgate.
^ Remove six screws securing load-space carpet retainer to the floor and remove retainer. (Figure 1)
^ Release and fold carpet back for access.
^ Fold back sound insulation to reveal fuel pump access panel.
^ Remove fuel pump access panel. (Figure 2)
^ Disconnect electrical connector from fuel pump tank unit. (Figure 3)
^ 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, use two open-end wrenches to loosening or tightening unions.
CAUTION:
ALWAYS install plugs to open connections to prevent contamination.
^ Disconnect fuel line unions from fuel pump.
(Arrowed in Figure 4)
^ Remove absorbent cloth.
^ Using LRT-19-001 remove locking ring securing fuel pump tank unit assembly to fuel tank. (Figure 5)
^ Carefully release fuel pump tank unit assembly.
^ Remove and discard tank unit seal.
NOTE:
Always follow the manufacturer's instructions for the connection and safe use of the fuel recovery system.
^ Using a fuel recovery system, drain the remaining fuel from the tank into a sealed container.
3. Remove Tank from vehicle 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.
^ Remove fuel tank vent hose retaining bracket securing nut and bolt. (Figure 7)
^ Disconnect fuel tank vent hose. (Figure 8)
^ Disconnect fuel tank filler hose from fuel tank filler neck. (Figure 9)
^ Remove nut and bolt securing right-hand side fuel tank strap. (Figure 10)
^ Remove rear towing eyes. (Figure 11).
^ Remove rear anti-roll bar bracket securing nuts and bolts.
^ Allow bar to swing down clear of fuel tank. (Figure 12)
^ Remove back two bolts and nut plates securing fuel tank cradle. (Figure 13)
NOTE:
Assistance will be required to support the fuel tank during the final removal steps.
^ Remove front nuts, bolts and washers.
^ Remove the fuel tank cradle.
^ With assistance lower and remove fuel tank assembly from vehicle.
4. Install replacement gas tank into vehicle as follows:
NOTE:
Connect the fuel filler hose while fitting the fuel tank. Assistance will be required to install the tank.
^ 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 and verify proper routing.
^ Install fuel tank vent hose retaining bracket nut and bolt.
^ Connect evaporative control pipe at green end of speedfit connector.
^ Install tie strap securing evaporative control pipe to fuel tank filler hose.
5. If equipped, install rear step as follows:
^ With assistance, position the step assembly to chassis.
^ Support the step assembly.
^ Install nut, bolt, and washer securing step to chassis and tighten to 40 Nm (30 lbf.ft).
^ Connect damper.
^ Install nut and washer securing damper to the step assembly.
6. Install 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 and 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.
^ Re-connect electrical connector to fuel pump tank unit.
^ Install fuel pump access panel and secure with screws.
^ Reposition sound insulation.
^ Reposition carpet.
^ Install load-space carpet retainer and secure with screws.
7. Close tailgate.
8. Refill fuel tank with extracted fuel.
9. Install fuel filler cap and check for correct seating.
10. Close fuel filler flap.
11. Connect the battery ground cable.
NOTE:
Campaign labels are no longer required for Safety Recall Campaigns.
12. When all repair work is complete, claim campaign code B156 and correct Option code.