Land Rover 2000-05

Removal & Installation

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CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the fuel pump, then using a fuel recovery appliance, drain the fuel from the tank into a sealed container. Follow the manufacturer's instructions for the connection and safe use of the appliance.
    CAUTION
    The fuel tank must be drained before it is removed from the vehicle.

  6.  
  7. Remove intermediate exhaust pipe.
  8.  
  9. Remove the propeller shaft.
  10.  
  11. Remove RH rear wheel arch liner.
  12.  
  13. Remove tamper proof cover from filler hose clip and loosen clip.

    Click image to see an enlarged view

    Fig. Remove tamper proof cover from filler hose clip and loosen clip

  14.  
  15. Support the weight of rear sub-frame and remove 4 bolts securing sub-frame to body.

    Click image to see an enlarged view

    Fig. Support the weight of rear sub-frame and remove 4 bolts securing sub-frame to body

  16.  
  17. Carefully lower the sub-frame.
    WARNING
    NEVER let the sub-frame to hang on rear brake hoses.

  18.  
  19. With the help of an assistant, remove 4 bolts securing fuel tank to body and remove tank.
    NOTE
    Pull vent and breather hoses through body while lowering fuel tank.



    Click image to see an enlarged view

    Fig. With the help of an assistant, remove 4 bolts securing fuel tank to body and remove tank

  20.  
  21. Remove fuel tank from cradle. If necessary, remove the heat and fire shields.

    Click image to see an enlarged view

    Fig. Remove fuel tank from cradle. If necessary, remove the heat and fire shields

  22.  
  23. Remove clips from breather hose and vent pipes.
  24.  
  25. Disconnect the breather hose and vent pipe from the fuel tank.

    Click image to see an enlarged view

    Fig. Disconnect the breather hose and vent pipe (arrows) from the fuel tank

  26.  

To install:

  1. Connect breather hose and vent pipe to tank, secure with clips.
  2.  
  3. Position heat and fire shields. Fit cradle to fuel tank.
  4.  
  5. With assistance, fit bolts securing fuel tank to body and tighten to 45 Nm.
    NOTE
    Pass vent and breather hoses through body while fitting tank.

  6.  
  7. Raise sub-frame, fit bolts and tighten to 135 ft. lbs. (190 Nm).
  8.  
  9. Connect breather hose to filler neck, fit and secure clip.
  10.  
  11. Install the RH rear wheel arch liner.
  12.  
  13. Install the propeller shaft.
  14.  
  15. Install the intermediate exhaust pipe.
  16.  
  17. Install the fuel pump assembly, as outlined in this section.
  18.  
  19. Connect battery earth lead.
  20.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Using a fuel recovery appliance, drain the fuel from the tank into a sealed container. Follow the manufacturer's instructions for the connection and safe use of the appliance.
  2.  
  3. Raise and safely support the rear of the vehicle.
    CAUTION
    Never work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

  4.  
  5. Loosen the securing clip and release filler tube from fuel tank.
  6.  
  7. Disconnect fuel tank vent pipe from filler tube.

    Click image to see an enlarged view

    Fig. Loosen the securing clip (4) and release filler tube from fuel tank. Disconnect fuel tank vent pipe from filler tube (4)

  8.  
  9. Support weight of fuel tank underneath cradle.
  10.  
  11. Remove the 2 nuts and 2 bolts securing the cradle to chassis.
  12.  
  13. With the help of an assistant, lower the left side of the fuel tank then carefully remove the fuel tank from the chassis.
  14.  
  15. Remove the cradle from the fuel tank.

    Click image to see an enlarged view

    Fig. View of the cradle nuts and bolts (7) and cradle (9)

  16.  

To install:

  1. Fit breather hose to fuel tank and secure with clip.
  2.  
  3. Position heat shield and secure with scrivets.
  4.  
  5. With assistance, position fuel tank and cradle.
  6.  
  7. Install the nuts and bolts securing cradle to chassis, then tighten the bolts to 33 ft. lbs. (45 Nm) and the nuts to 19 ft. lbs. (26 Nm).
  8.  
  9. Connect the vent hose.
  10.  
  11. Connect the breather and filler hoses and secure with clips.
  12.  
  13. Carefully lower the vehicle.
  14.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel from the tank
     
    Fuel filler tube from the tank
     
    Feed pipe at the rear of the filter
     
    Return line
     

  6.  
  7. Support the fuel tank with a jack.
  8.  
  9. Remove the 3 nuts and 2 bolts securing the fuel tank cradle-to-the floor pan.
  10.  
  11. Lower the tank about 6 inches (150mm) and unplug the wiring connectors.
  12.  
  13. Remove the tank/cradle assembly.
  14.  
  15. Remove the tank from the cradle.
  16.  

To install:

  1. Install the fuel tank in the vehicle, tighten the mounting bolts to 33 ft. lbs. (45 Nm), and be sure to connect the fuel tank vent hose and filler neck.
  2.  
  3. Lower the vehicle and fill the fuel tank with at least 10 gallons of fuel. Connect the negative battery cable. Turn the ignition key to RUN for 3 seconds repeatedly, 5-10 times, to pressurize the system. Check for leaks.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Disconnect the negative battery cable.
  2.  
  3. Using a fuel recovery appliance, drain the fuel from the tank into a sealed container. Follow the manufacturer's instructions for the connection and safe use of the appliance.
  4.  
  5. Raise and safely support the rear of the vehicle.
    CAUTION
    Never work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.


    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  6.  
  7. Remove 4 nuts and remove fuel tank RH access cover.
  8.  
  9. Disconnect multiplug from fuel pump.
  10.  
  11. Remove the center console.
  12.  
  13. Release cable securing clip from parking brake compensator, release parking brake cables from compensator and remove securing clip.

    Click image to see an enlarged view

    Fig. Release cable securing clip from parking brake compensator, release parking brake cables from compensator and remove securing clip

  14.  
  15. Remove the rear propeller shaft.
  16.  
  17. Withdraw parking brake cables from body and move aside for access.
  18.  
  19. Remove RH rear wheel liner.
  20.  
  21. Release clip from breather hose and disconnect breather hose from filler neck.
    CAUTION
    Fuel vapor is extremely 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.



    Click image to see an enlarged view

    Fig. Release clip from breather hose and disconnect breather hose from filler neck

  22.  
  23. Release fuel tank breather and charcoal canister vent pipes from clip on filler neck.
  24.  
  25. Remove clip from breather hose and vent pipe.
  26.  
  27. Remove 16 bolts and 4 nuts securing fuel tank shields.

    Click image to see an enlarged view

    Fig. Remove 16 bolts and 4 nuts securing fuel tank shields

  28.  
  29. Disconnect 3 pipes from charcoal canister, remove 2 Torx® bolts and remove charcoal canister.
  30.  
  31. Loosen 4 bolts securing rear sub-frame to allow removal of tank shields. Collect fuel tank shields.
  32.  
  33. Disconnect fuel tank filler hose from fuel tank filler neck.
  34.  
  35. Remove 2 screws securing fuel filter and release fuel filter from mounting brackets.

    Click image to see an enlarged view

    Fig. Remove 2 screws securing fuel filter and release fuel filter from mounting brackets

  36.  
  37. Position container to catch fuel spillage.
  38.  
  39. Disconnect 3 fuel hoses and 1 reference pipe, remove fuel filter.
    CAUTION
    The spilling of fuel is unavoidable during this procedure. Make sure all necessary precautions are taken to prevent fire and explosion.

  40.  
  41. Remove container.
  42.  
  43. With the help of an assistant, remove 5 bolts securing fuel tank to body, lower and remove tank.
    NOTE
    Pull vent and breather hoses through body while lowering fuel tank.



    Click image to see an enlarged view

    Fig. With the help of an assistant, remove 5 bolts securing fuel tank to body, lower and remove tank

  44.  
  45. Installation is the reverse of the removal procedure.
  46.  

 
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