Land Rover 2000-05

Fuel Pump

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Removal & Installation





Click image to see an enlarged view

Fig.

  1. Remove 5 trim clips holding lower edge of right D-post trim casing.
  2.  
  3. If equipped with rear in-car entertainment (ICE) controls, remove screw securing remote ICE controls to right trim casing. Release ICE controls from casing and detach connectors.
  4.  
  5. Partially remove tail door aperture seal in area of right side trim casing.
  6.  
  7. Remove 2 trim clips holding right side trim casing to body.
  8.  
  9. Remove rear lamp access panel from right side trim casing.
  10.  
  11. Remove trim clip securing right side trim casing to lower E-post.
  12.  
  13. Remove trim casing.
  14.  
  15. Pull back cargo space carpet from over fuel pump access panel.
  16.  
  17. Remove 6 screws and remove access panel.
  18.  
  19. Disconnect plug and fuel hose from fuel pump housing.
  20.  


CAUTION
Always plug all openings to prevent contamination.

  1. Disconnect pressure sensor pipe from fuel pump housing.
  2.  
  3. Install tool LRT-19-009 onto locking ring of fuel pump housing.
  4.  
  5. Remove locking ring.
  6.  
  7. Remove fuel pump housing.
  8.  
  9. Remove and discard sealing ring from fuel pump housing.
  10.  

To install:

  1. Clean fuel pump housing and mating face on fuel tank.
  2.  
  3. Install new seal to mating face on fuel tank.
  4.  
  5. Install fuel pump housing to fuel tank and use LRT-19-009 to install and set locking ring.
  6.  
  7. Connect multiplug and fuel hose to fuel pump housing.
  8.  
  9. Connect pressure sensor pipe to fuel pump housing.
  10.  
  11. Install access panel and secure with screws.
  12.  
  13. Reposition cargo space carpet.
  14.  
  15. If equipped with 3rd row seats, install bolt securing lower mounting of 3rd row seat belt to bolt and tighten to 37 ft. lbs. (50 Nm).
  16.  
  17. Install trim casing and components in reverse of removal procedure.
  18.  
  19. Install 3rd row right side seat.
  20.  
  21. Reconnect battery ground cable.
  22.  
  23. Install battery cover.
  24.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  


NOTE
The fuel pump and fuel gauge tank unit are integral parts of fuel pump housing and cannot be replaced individually.

  1. Remove battery cover.
  2.  
  3. Disconnect battery ground cable.
  4.  
  5. If equipped with 3rd row seat, remove right seat.
  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this 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.  
  17. Remove any dirt that has accumulated around the fuel pump flange so it will not enter the fuel tank during removal and installation.

    Click image to see an enlarged view

    Fig. Fuel pump mounting

  18.  
  19. Disconnect the breather hose from the pressure sensor.
  20.  
  21. Disconnect the hoses from the pump.
  22.  
  23. Using a locking ring tool, such as LRT 19-009, unscrew the retaining ring from the pump flange.
    NOTE
    A lifting ring is provided to pull the unit out. Don-t pull on any other parts!

  24.  
  25. Remove the fuel pump and discard the seal ring. Separate the fuel pump from the sending unit, if required.
  26.  

To install:

  1. Clean the fuel pump mounting flange and tank mounting surface.
  2.  
  3. Apply a light coating of sealer on a new seal ring.
  4.  
  5. Install the fuel pump on the sending unit, if removed. Install the fuel pump assembly in the tank and tighten it to 26 ft. lbs. (35 Nm).
  6.  
  7. 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.
  8.  
  9. 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.
  10.  
  11. Start the engine and check for leaks.
  12.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery ground lead.
  4.  
  5. Properly depressurize fuel system before proceeding.
    WARNING
    Depressurize the system before disconnecting any components. Fuel pressure will be present in the system even if the ignition has been switched off for some time.

  6.  
  7. Open right side rear and tail doors.
  8.  
  9. Fold right side rear seat forward.
  10.  
  11. Remove 2 fasteners securing front and rear carpets.
  12.  
  13. Pull back load space carpet from fuel pump access panel.
  14.  
  15. Remove 6 screws securing access panel.
  16.  
  17. Remove access panel.
    WARNING
    The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.

  18.  
  19. Detach the connector and fuel hose from fuel pump housing.
    CAUTION
    Always fit plugs to open connections to prevent contamination.

  20.  
  21. Use LRT-19-009 to remove locking ring from fuel pump housing.
  22.  
  23. Remove fuel pump housing and discard sealing ring.
  24.  

To install:

  1. Clean fuel pump housing and mating face on fuel tank.
  2.  
  3. Fit new seal to fuel pump housing.
  4.  
  5. Fit fuel pump housing to fuel tank, fit and tighten locking ring to 26 ft. lbs. (35 Nm) using LRT-19-009.
  6.  
  7. Connect multiplug and fuel hose to fuel pump housing.
  8.  
  9. Fit access panel and secure with screws.
  10.  
  11. Position carpet and secure with fasteners.
  12.  
  13. Reposition rear seat.
  14.  
  15. Close rear and tail doors.
  16.  
  17. Connect the negative battery cable.
  18.  

  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.  
  17. Remove any dirt that has accumulated around the fuel pump flange so it will not enter the fuel tank during removal and installation.

    Click image to see an enlarged view

    Fig. Fuel pump mounting-Discovery (2000-02) and Range Rover (2000-02)

  18.  
  19. Disconnect the breather hose from the pressure sensor.
  20.  
  21. Disconnect the hoses from the pump.
  22.  
  23. Using a locking ring tool, such as LRT 19-009, unscrew the retaining ring from the pump flange.
    NOTE
    A lifting ring is provided to pull the unit out. Don-t pull on any other parts!

  24.  
  25. Remove the fuel pump and discard the seal ring. Separate the fuel pump from the sending unit, if required.
  26.  

To install:

  1. Clean the fuel pump mounting flange and tank mounting surface.
  2.  
  3. Apply a light coating of sealer on a new seal ring.
  4.  
  5. Install the fuel pump on the sending unit, if removed. Install the fuel pump assembly in the tank and tighten it to 26 ft. lbs. (35 Nm).
  6.  
  7. 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.
  8.  
  9. 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.
  10.  
  11. Start the engine and check for leaks.
  12.  

  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    The fuel pump and fuel gauge tank unit are integral parts of fuel pump housing and cannot be replaced individually.


    NOTE
    Before disconnecting the battery, remove the ignition key. If the key is not removed, the fuel gauge will remember its previous position and result in inaccurate readings.

  2.  
  3. Disconnect battery ground cable.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the fuel tank.
  8.  
  9. At the rear of the vehicle, remove both D pillar trim finish panels.
  10.  
  11. Remove the spare wheel hold down straps.
  12.  
  13. Pull back cargo space carpet from over fuel pump access panel.
  14.  
  15. Remove 4 nuts and remove right side fuel pump access panel.
  16.  
  17. Disconnect fuel pump connector.
  18.  
  19. Disconnect fuel feed and return pipes from pump.
  20.  
  21. Remove left side fuel pump access panel and from the opening, disconnect the fuel gauge sender connector from the fuel pump body.
  22.  
  23. Install tool LRT-19-009 onto locking ring of fuel pump housing.
  24.  
  25. Remove locking ring.
  26.  
  27. Remove fuel pump assembly.
  28.  
  29. Remove and discard sealing ring from fuel pump housing.
  30.  

To install:

  1. Clean fuel pump housing and mating face on fuel tank.
  2.  
  3. Install new seal to mating face on fuel tank.
  4.  
  5. Install the fuel pump.
  6.  
  7. Connect the fuel gauge sender to the pump.
  8.  
  9. Use LRT-19-009 to install and set locking ring.
  10.  
  11. Connect the fuel feed and return lines.
  12.  
  13. Connect the fuel pump connector.
  14.  
  15. Install access panel and secure with screws.
  16.  
  17. Reposition cargo space carpet.
  18.  
  19. Install spare wheel hold down straps.
  20.  
  21. Install D pillar trim finish panels.
  22.  
  23. Fill the tank with at least 10 gallons of gasoline.
  24.  
  25. Reconnect battery ground cable.
  26.  
  27. Start the vehicle and check for leaks.
  28.  

 
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