Removal and installation of the fuel tank 4.4L (Discovery 3)

Removing

WARNING: The vehicle must be kept in an enclosed area with good ventilation. Signs must be posted around the vehicle "No smoking! vapors of gasoline!"

WARNING: Do not carry or use a cell phone while working on or near any fuel related parts. In such situations, highly flammable vapors are always present that can ignite. Failure to follow these instructions may result in injury.

WARNING: Do not smoke or walk with a lit cigarette or open flame of any type while working on or near fuel related items. In such situations, highly flammable vapors are always present that can ignite. Failure to follow these instructions may result in injury.

CAUTION: Some fuel will inevitably spill during this operation. Ensure that all necessary precautions have been taken to prevent fire and explosion.

CAUTION: Before disconnecting or dismantling parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.

1. Disconnect the wire "masses" from the battery. For more information refer to Specification.

2. Drain the fuel from the fuel tank. For more information refer to Emptying the fuel tank (19.55.02)

3.

WARNING: It is forbidden to carry out work on a vehicle standing on only one jack. Always support the vehicle with jack stands.

Raise and support the vehicle.

4. Remove the fuel tank heat shield. Remove 3 bolts and remove 2 nuts.



5.

CAUTION: Before disconnecting or dismantling parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.

Disconnect the fuel filler neck from the fuel filler hose.

• Remove the tamper-proof cover.
• Remove and discard hose clamp.

6.

CAUTION: Before disconnecting or dismantling parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.

Disconnect the fuel supply and purge line quick coupling at the front of the fuel tank.



7.

CAUTION: Before disconnecting or dismantling parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.

Disconnect the fuel tank vent line.



8. Release the fuel tank wiring harness.


9. Release the parking brake cable emergency release cable. Release from 4 clips.

10. Remove the 2 parking brake cable emergency release cable clamps.



11.

CAUTION: Secure the assembly to the transmission jack.

WARNING: Do not lower the fuel tank lower than 250 mm (9.75 inches)

ATTENTION: Please note that there are two washers on the rear bolt.

Use a transmission jack to lower the fuel tank just enough to access the top of the tank. Turn out 6 bolts.



12. Disunite an electric socket of the module of the fuel pump.



13. Release the purge line from the top of the fuel tank.

• Remove self-adhesive tape.
• Release from 5 clips.

14. Remove the fuel tank.

15.

NOTE: Do not proceed with further disassembly if the part is being removed only for access.

With assistance, remove the fuel tank from the transmission jack.

16.

CAUTION: Before disconnecting or dismantling parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.

Remove the fuel tank vent line.

• Disconnect the quick connector.
• Release from 3 clips.

17.

CAUTION: Before disconnecting or dismantling parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.

Disconnect the fuel supply line.

• Disconnect the quick connector.
• Release from 2 clips.

18.

CAUTION: Before disconnecting or dismantling parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.

NOTE: Remember the position of the part.

Loosen the fuel pump module access flange.

• Loosen the screw.
• Remove clamp.

19.

CAUTION: Before disconnecting or dismantling parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.

Remove the fuel pump module access flange.

• Disconnect the ventilation line.
• Disconnect the fuel supply line.
• Disconnect 3 electrical connectors.
• Remove and discard the O-ring.

20. Remove the fuel pump module.

• Release the tape.
• Release the fuel pressure regulator.
• Disconnect 2 fuel lines.

21. Remove the front fuel tank level sensor.

• Release the wire.
• Release the clamp.

22.

CAUTION: Before disconnecting or dismantling parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.

Remove the filler hose.

• Remove the tamper-proof cover.
• Remove and discard hose clamp.

23. Remove the fuel tank bracket.

• Remove 2 clips.
• Turn out two bolts.
• Remove the mounting plate.

Installation

1. Install the fuel tank bracket.

• Install the base plate.
• Install clamps.
• Tighten the bolts (tightening torque 3.5 Nm).

2.

CAUTION: Tighten the tamper-proof clamp until the hex head breaks off.

Install the filler hose. Install a new clip.

3. Install the front fuel tank level sensor.

• Lock the clamp.
• Fasten the wire.

4. Install the fuel pump module.

• Connect the fuel lines.
• Secure with tape.
• Attach the fuel pressure regulator.

5. Install the fuel pump module access flange.

• Clean the contact surfaces of the parts.
• Install a new seal.
• Connect 3 electrical connectors.
• Connect the fuel supply line.
• Connect the ventilation line.

6.

CAUTION: Make sure the seal is installed correctly.

Install the fuel pump module access flange.

• Install clamp.
• tighten screw (tightening torque 4 Nm).

7. Install the fuel supply line.

• Connect the quick connector.
• Secure with 2 clips.

8. Install the ventilation line.

• Connect the quick connector.
• Secure with 3 clips.

9. With assistance, mount the fuel tank from the transmission jack.

10. Put the fuel tank on the car.

11. Attach the purge line to the top of the fuel tank.

• Fasten with clips.
• Install self-adhesive tape.

12. Dock the electrical connector.

13.

ATTENTION: Please note that there are two washers on the rear bolt.

Install the fuel tank. Tighten the bolts (tightening torque 45 Nm).

14. Install the 2 parking brake cable emergency release cable clips.

15. Attach the parking brake cable emergency release cable. Secure with 4 clips.

16. Attach the fuel tank wiring harness.

17. Connect the fuel tank vent line.

18. Attach the supply fuel line and purge line.

19.

CAUTION: Tighten the tamper-proof clamp until the hex head breaks off.

Attach the fuel tank filler neck. Install a new clip.

20. Install the fuel tank heat shield.

• Tighten the bolts (tightening torque 6 Nm).
• Tighten nuts (tightening torque 3 Nm).

21. Pour fuel into the fuel tank. For more information refer to Emptying the fuel tank (19.55.02)