Removal and installation the fuel tank (Defender 2007+)

Special tool(s)

	Powertrain Jack Assembled HTJ-1200-02
	Fuel tank wrench 310-118

Removal

Warnings:

• After completing repairs, inspect the fuel system for leaks. Failure to do so could result in injury.
• Do not carry or use a cell phone while working with or in the immediate vicinity of any fuel related components. There is a risk of ignition of flammable vapors. Failure to follow these instructions may result in injury.
• Do not smoke or carry a lighted cigarette or open flame of any type when working on or near fuel-related components. There is a risk of ignition of flammable vapors. Failure to follow these instructions may result in injury.
• If fuel gets into your eyes, rinse them with cold water or a special eye wash solution and seek medical attention immediately.
• This procedure involves handling fuel. Always be prepared for possible fuel splashing and use caution when handling fuel. Failure to follow these instructions may result in injury.
• Wash your hands thoroughly after handling fuel, as prolonged contact with the skin may cause irritation. If irritation occurs, seek medical attention.

Warnings:

• Diesel fuel injection equipment is manufactured to very precise tolerances and very small clearances. Therefore, absolute cleanliness is required when working with these components.
• Be sure to plug all open ports and lines. Failure to do so may result in dirt entering the fuel injection system.
• Keep the area of the service station where the vehicle is being worked on as clean and dust-free as possible. Dirt and dust from clutch, brake, machining, or welding work can contaminate the fuel system and cause problems later.

1.

WARNING: Never work on a vehicle supported only by a jack. Always support the vehicle with special stands.

Raise and support the vehicle.

2. Disconnect the ground wire from the battery.

For more information, refer to the chapter: Disconnecting and connecting the battery (414-01 Battery, Battery Mounting and Cables, General Procedures).

3.

WARNING: Some fuel will inevitably spill during this operation. Make sure that all necessary precautions are taken to prevent fire and explosion.

Drain the fuel from the fuel tank.

For more information, refer to the chapter: Draining the fuel tank (310-00 Fuel Delivery System - General Information, General Procedures).

4.

CAUTION: Plug all openings. Use new caps.

Remove the fuel tank filler neck. Loosen the clamp.



5. Remove the fuel tank vent line.

• Release from the clamp.
• Cut the clamp.

6. Using the special tool, support the fuel tank.





7. Lower the fuel tank.

• Remove two bolts.
• Unscrew 2 nuts.

8.

CAUTION: Plug all openings. Use new caps.

Disconnect the filler neck vent hose. Release the clamp.



9.

CAUTION: Plug all openings. Use new caps.

NOTE: Mark the installation position of the fuel lines.

Remove the fuel tank and its support bracket.

• Disconnect 2 fuel lines.
• Disconnect the electrical connector.

10.

NOTE: Do not perform further disassembly if the component is removed only for access.

Remove the fuel tank heat shield. Remove the 3 clips.



11. Remove the fuel tank vent line. Release the clamp.

12. Remove the fuel level sensor.

• Using a special tool, remove the retaining ring.
• Remove the seal and dispose of it.

Installation

1.

NOTE: Clean the contact surfaces of the parts.

Install the fuel level sensor.

• Install a new seal.
• Using the special tool, tighten the retaining ring to a torque of 35 Nm.

2. Install the fuel tank vent line. Secure with a clamp.



3. Install the fuel tank heat shield. Install 3 clamps.

4.

NOTE: Remove and discard plugs.

Using a special tool, lift the fuel tank and its support bracket.

• Connect the 2 fuel lines.
• Connect the plug connector.

5. Connect the fuel tank vent hose. Secure with a clamp.

6. Using a special tool, install the fuel tank and its support bracket.

• Tighten the bolts to 45 Nm.
• Tighten the nuts (tightening torque 25 Nm).

7. Remove the fuel tank vent line.

• Secure in the clamp.
• Secure the pieces with wire ties.

8. Connect the fuel tank filler pipe. Tighten the clamp.

9.

WARNING: Some fuel will inevitably spill during this operation. Make sure that all necessary precautions are taken to prevent fire and explosion.

Fill the fuel tank with fuel.

10. Connect the ground wire to the battery.

For more information, refer to the chapter: Connecting the Battery (414-01 Battery, Battery Mounting and Cables, General Procedures).