Removal and installation the fuel tank 2.7L (Discovery 3)

Removal

All cars

1. Disconnect the ground cable from the battery. For more information, refer to Specification.

2. Drain the fuel from the fuel tank. For more information, refer to Draining the Fuel Tank (19.55.02)

3.

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

Raise and support the vehicle.

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



5.

CAUTION: Before disconnecting or disassembling parts, make sure that the area around the contact surfaces and connections is clean. To avoid contamination of the system, close all open connections with plugs.

Disconnect the fuel tank filler neck from the filler neck hose.

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

6.

CAUTION: Secure the assembly to a transmission jack.

Lower the fuel tank using a transmission jack. Remove the 5 bolts.



7. Release the parking brake cable emergency release cable. Release it from the 4 clamps.

8.

NOTE: Remember the position of the part.

Disconnect the fuel tank vent line and fuel line.

• Remove the holders.
• Release from the clamps.
• Remove the adhesive tape.

9.

CAUTION: Before disconnecting or disassembling parts, make sure that the area around the contact surfaces and connections is clean. To avoid contamination of the system, close all open connections with plugs.

Disconnect the 2 fuel tank vent lines. Release the clamp.

Cars with fuel-fired auxiliary heater

10.

CAUTION: Before disconnecting or disassembling parts, make sure that the area around the contact surfaces and connections is clean. To avoid contamination of the system, close all open connections with plugs.

Disconnect the fuel line from the fuel fired auxiliary heater. Release the clamp.

All cars

11.

CAUTION: Before disconnecting or disassembling parts, make sure that the area around the contact surfaces and connections is clean. To avoid contamination of the system, close all open connections with plugs.

Disconnect 2 fuel lines. Release 2 clamps.

12. Disconnect the fuel pump module electrical connector.

13. Remove the fuel tank.



14.

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

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

15.

CAUTION: Before disconnecting or disassembling parts, make sure that the area around the contact surfaces and connections is clean. To avoid contamination of the system, close all open connections with plugs.

NOTE: Remember the position of the part.

Release the fuel pump module access flange.

• Loosen the screw.
• Remove the clamp.

16.

CAUTION: Before disconnecting or disassembling parts, make sure that the area around the contact surfaces and connections is clean. To avoid contamination of the system, close all open connections with plugs.

Remove the fuel pump module access flange.

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

17. Remove the fuel pump module.

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

18. Remove the front fuel tank level sensor.

• Release the wire.
• Release the clamp.

19. Remove the fuel tank bracket.

• Remove 2 clamps.
• Remove two bolts.
• Remove the mounting plate.

Installation

All cars

1. Install the fuel tank bracket.

• Install the support plate.
• Install the clamps.
• Tighten the bolts (tightening torque 10 Nm).

2. Install the front fuel tank level sensor.

• Secure the clamp.
• Secure the wire.

3. Install the fuel pump module.

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

4. Install the fuel pump module access flange.

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

5.

CAUTION: Make sure the seal is installed correctly.

NOTE: Align the part to its original position.

Secure the fuel pump module access flange.

• Install the clamp.
• Tighten the screw (tightening torque 4 Nm).

6. With assistance, place the fuel tank on the transmission jack.



7. Place the fuel tank on the vehicle.

8. Connect the fuel lines. Secure with a clamp.

Cars with fuel-fired auxiliary heater

9. Attach the fuel line of the fuel-fired auxiliary heater. Secure with a clamp.

All cars

10. Connect the ventilation lines. Secure with a clamp.

11. Connect the electrical connector.

12. Secure the ventilation line and fuel line.

• Secure with clamps.
• Install the holders.
• Install the self-adhesive tape.

13. Secure the parking brake cable emergency release cable. Secure with 4 clamps.

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

15.

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

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

16. Install the fuel tank heat shield.

• Tighten the bolts (tightening torque 5 Nm).
• Tighten the nuts (tightening torque 3 Nm).

17. Fill the fuel tank with fuel. For more information, refer to Draining the Fuel Tank (19.55.02)

18. Bleed the fuel system. For more information, refer to Bleeding the Low-Pressure Fuel System (19.50.07)