Fuel Pump: Service and Repair

Fuel Tank Pump


Service repair no - 19.45.03


NOTE: This procedure has been updated per Land Rover Technical Bulletin LTB00066

Remove

CAUTION: Before disconnecting the battery, ensure that the key is removed from the ignition. Failure to remove the key will result in the fuel gauge memorising its needle position before disconnection and reverting to it on re-connection of the battery.

1. Disconnect battery negative cable.

CAUTION: In many countries it is against the law for a vehicle owner or an unauthorised dealer to modify or tamper with emission control equiptment. In some cases, the vehicle owner and/or dealer may even be liable for prosecution.

2. Open fuel filler flap and remove cap.

WARNING: Fuel must not be extracted or drained from any vehicle while it is over a pit. Extraction or draining of fuel must be carried outin a well ventilated area.

3. Connect fuel recovery appliance ground lead to the vehicle.


WARNING: Fuel vapor is highly flammable and in confined spaces is also explosive and toxic. Always nave a fire extinguisher containing foam, CO2, gas or powder close at hand when handling or draining fuel.

4. Install fuel recovery appliance extraction hose, insert hose through filler neck, turning hose slightly if necessary. Chamfer end of bowser hose to approximately 30° to aid entry.

WARNING: Follow the manufacturers instructions for the connection and safe use of the appliance.

5. Using a fuel recovery appliance, drain approximately 25L (6.6 gal.)

6. Remove extraction hose from fuel filler neck, disconnect negative lead from recovery appliance.

7. Remove 'D' post trim casing.

8. Remove opposite 'D' post trim.

9. Remove spare wheel cover.

10. Remove two Allen bolts securing spare wheel removal straps to cross member and move straps aside.





11. Remove four bolts securing rear seat catches and remove rear seat catches.





12. Release carpet, fold forward and tie aside.

13. Remove four nuts and reposition fuel tank LH access cover.





14. Clean area surrounding locking ring.

15. Using LRT-19-009 remove locking ring securing access plug to fuel tank.





CAUTION: Before disconnecting or removing components, ensure the immediate area around joint faces and connections are clean. Plug open connections to prevent contamination.

16. Remove access plug and discard fuel tank seal.

WARNING: Fuel vaporis highly flammable and in confined spaces is also explosive and toxic. Always have a fire extinguisher containing foam, CO2, gas or powder close at hand when handling or draining fuel.

17. Remove four nuts and reposition fuel tank RH access cover.





WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.

18. Position a container to collect any spillage.

19. Disconnect the electrical connection from fuel pump.





CAUTION: Before disconnecting or removing components, ensure the immediate area around joint faces and connections are clean. Plug open connections to prevent contamination.

20. Noting fitted position, disconnect fuel feed and return pipes from fuel pump.

21. Clean area surrounding lock ring.

22. Release clip, disconnect combined electrical connector and fuel pipe connection from fuel pump body.





23. Using LRT-19-009 remove locking ring securing fuel pump to fuel tank.





24. Remove fuel pump assembly.

25. Remove and discard seal.

Install

1. Install a new fuel pump assembly seal.
.
2. Install fuel pump assembly.

3. Using LRT-19-009 install locking ring and tighten to 35 Nm (26 ft. lbs.).

4. Connect combined electrical connector and fuel pipe connection to fuel pump body.

5. Connect fuel pipes to pump.

6. Remove container.

7. Connect electrical connector to fuel pump.

8. Position fuel tank RH access panel, fit nuts and tighten to 10 Nm (7 ft. lbs.).

9. Clean fuel tank access plug and install new tank seal.

10. Using LRT-19-009 install locking ring and tighten to 35 Nm (26 ft. lbs.).

11. Install fuel tank LH access panel, install nuts and tighten to 10 Nm (7 ft. lbs.)

12. Install carpet.

13. Position spare wheel release straps, install bolts and tighten to 25 Nm (18 ft. lbs.)

14. Install spare wheel cover.

15. Install rear seat catches, install bolts and tighten.

16. Install 'D' post trim casing.

17. Replenish fuel as required.

18. Install filler cap and close fuel filler flap.

19. Connect the battery negative ground cable.

20. Turn ignition key to position 1; allow time for fuel pump to prime.