Fuel Delivery System Land Rover Range Rover L322

FUEL DELIVERY SYSTEM SPECIFICATIONS

FUEL HANDLING PRECAUTIONS

Fuel vapor is highly flammable and in confined spaces is also explosive and toxic. The vapor is heavier than air and will always fall to the lowest level. The vapor can be easily distributed throughout a workshop by air currents; consequently, even a small spillage of fuel is potentially very dangerous.

The following information provides basic precautions which must be observed if fuel is to be handled safely. It also outlines other areas of risk which must not be ignored. This information is issued for basic guidance only, if in doubt consult your local Fire Officer.

GENERAL

Always have a fire extinguisher containing FOAM, CO2, GAS or POWDER close at hand when handling or draining fuel or when dismantling fuel systems. Fire extinguishers should also be located in areas where fuel containers are stored.

Always disconnect the vehicle battery before carrying out dismantling or draining work on a fuel system.

Whenever fuel is being handled, drained or stored, or when fuel systems are being dismantled, all forms of ignition must be extinguished or removed; any headlamps must be flameproof and kept clear of spillage.

FUEL TANK DRAINING

Fuel tank draining should be carried out in accordance with the procedure outlined in the FUEL DELIVERY section of this manual and observing the following precautions.

FUEL TANK REMOVAL

When the fuel line is secured to the fuel tank outlet by a spring steel clip, the clip must be released before the fuel line is disconnected or the fuel tank is removed. This procedure will avoid the possibility of fumes in the fuel tank being ignited when the clip is released.

As an added precaution, fuel tanks should have a FUEL VAPOR warning label attached to them as soon as they are removed from the vehicle.

FUEL TANK REPAIRS - PLASTIC TANK

No attempt should be made to repair a plastic fuel tank. If the structure of the tank is damaged, a NEW tank must be fitted.

BODY REPAIRS

Plastic fuel pipes are particularly susceptible to heat, even at relatively low temperature, and can be melted by heat conducted from some distance away.

When body repairs involve the use of heat, all fuel pipes which run in the vicinity of the repair area must be removed, and the tank outlet plugged.

For fuel delivery system component locations (Scheme 1)or (Scheme 2).

Scheme 1

Scheme 2

The Land Rover V8 fuel delivery system comprises the following main components

1. Saddle Type Fuel Tank
2. Fuel Injectors
3. Non Return Fuel Rail
4. Fuel Pump
5. On Board Refuelling Vapor Recovery System (NAS Only)
6. Tank Leakage Detection System (NAS Only)

Fuel Tank

The fuel tank is constructed from molded plastic and is mounted under the rear seat just forward of the rear axle.

The fuel tank has a 98 L (25.8 gal) capacity and activates a low fuel warning lamp in the instrument pack when there is 12 liters in the tank. The tank is of the saddle tank design with a siphon jet pump in the left side to transfer fuel to the right side where the fuel pump is mounted. The fuel is delivered along pipes that run along the underside of the vehicle to a fuel rail mounted on the engine.

Fuel Filter

The fuel filter/pressure regulator is mounted on the lower right hand side of the tank. (Scheme 2)and (Scheme 3). The charcoal canister is mounted at the front of the tank on the right hand side. The components are covered by a plastic under tray to protect them when driving off-road. The undertray has an inspection cover to enable access to the charcoal canister and the fuel filter.

Scheme 3

Fuel Pump

The fuel pump comprises a pump, sender unit, pot and venturi. (Scheme 4) The unit has an integral filter inside the pot. The pump unit operates at 3.5 bar (50.75 psi) for 170-205 L/hr (the V8 has a maximum operating requirement of 90 L/hr).

The pump is controlled by the ECM via the fuel pump relay.

Should the fuel pump electrical connection need to be disconnected, it is imperative that the ignition should be switched off. If the ignition is on in any position the fuel gauge will memorize its last needle position prior to power down. Once power is restored the gauge will display the last remembered position regardless of the actual level of fuel in the tank. This will result in incorrect fuel gauge readings if the fuel tank has been drained and not filled with exactly the same quantity of fuel that was removed.

Scheme 4

Injectors

An electromagnetic, top feed fuel injector is installed in each cylinder inlet tract of the inlet manifolds. (Scheme 5) A common fuel rail supplies the injectors with fuel from a returnless fuel delivery system. The fuel in the fuel rail is maintained at a pressure of 3.5 bar (50.75 psi) by a pressure regulator incorporated in the fuel filter unit on the side of the fuel tank. A Schrader valve is installed in the fuel rail, to the rear of injector No. 7, to enable the fuel pressure to be checked.

Scheme 5

Fuel Rail

A contoured steel tube common fuel rail, supplies the injectors with fuel from the returnless fuel delivery system. (Scheme 6) The fuel in the fuel rail is maintained at a pressure of 3.5 bar (50.75 psi) by a pressure regulator incorporated into the fuel filter.

Scheme 6

Tank Leakage Detection (NAS Only)

Range Rover is equipped with a tank leakage detection system. The system is controlled by the ECM.

The tank leakage detection module is located inside the wheel arch at the top of the wheel arch next to the fuel filler neck on a metal bracket. (Scheme 7)

Scheme 7

Leak Detection Normal Operation

In its inactive state, filtered fresh air enters the evaporative system through the sprung open valve of the tank leakage detection module. When the ECM activates the tank leakage detection module for leak testing, it first activates only the pump motor. This pumps air through a reference orifice 0.5 mm (0.02") which causes the electric motor to draw a specific amperage value. This value is then equivalent to the size of the reference orifice. The solenoid valve is then energized which seals the EVAP system and directs the pump output to pressurize the EVAP system. (Scheme 8)

The system is detected as having a large leak if the amperage value is not realized, a small leak if the same reference amperage is realized or no leak if the amperage value is higher than the reference leak value.

The leak detection module ensures accurate fuel system leak detection for leaks as small as 0.5 mm (0.02"). The pump contains an integral DC motor which is activated directly by the engine control module. The ECM monitors the pump motor operating current as the measurement for detecting leaks.

In its inactive state the pump motor and the change over valve of the DC Motor LDP are not energized. When purge valve operation occurs filtered air enters the fuel system compensating for engine vacuum drawing on the hydrocarbon vapors stored in the charcoal canister.

The ECM only initiates a leak diagnosis test every second time the criteria are met. The criteria are as follows

1. Engine Off With Ignition Switched Off
2. Engine Control Module still in active state or what is known as "follow up mode" (Main Relay energized, control module and ECM components on-line for extended period after key off).
3. Prior to Engine/Ignition switch OFF condition, vehicle must have been driven for a minimum of 20 minutes.
4. Prior to minimum 20 minute drive, the vehicle must have been OFF for a minimum of 5 hours.
5. Fuel Tank Capacity must be between 15 and 85% (safe approximation between 1/4-3/4 of a tank).
6. Ambient Air Temperature between -7°C & 35°C (20°F & 95°F).
7. Altitude < 2500 m (8,202 feet)
8. Battery Voltage Between 11.5-14.5 Volts

When these criteria are satisfied every second time, the ECM will start the Fuel System Leak Diagnosis Test. The test will typically be carried out once a day i.e. once after driving to work in the morning, when driving home in the evening the criteria are once again met but the test is not initiated. The following morning, the test will run again.

Scheme 8

Phase 1 - Reference Measurement

The ECM activates the pump motor. The pump pulls air from the filtered air inlet and passes it through a precise 0.5 mm (0.02") reference orifice in the pump assembly. (Scheme 9)

The ECM simultaneously monitors the pump motor current flow. The motor current raises quickly and levels off (stabilizes) due to the orifice restriction. The ECM stores the stabilized amperage value in memory. The stored amperage value is the electrical equivalent of a 0.5 mm (0.02") leak.

Scheme 9

Phase 2 - Leak Detection

The ECM energizes the Change Over Valve allowing the pressurized air to enter the fuel system through the Charcoal Canister. The ECM monitors the current flow and compares it with the stored reference measurement over a duration of time. (Scheme 10)

Once the test is concluded, the ECM stops the pump motor and immediately de-energizes the change over valve. This allows the stored pressure to vent thorough the charcoal canister trapping hydrocarbon vapor and venting air to atmosphere through the filter.

Scheme 10

Test Results

The time duration varies between 45-270 seconds depending on the resulting leak diagnosis test results (developed tank pressure "amperage" within a specific time period). However the chart above depicts the logic used to determine fuel system leaks. (Scheme 11)

Scheme 11

FUEL SYSTEM - DEPRESSURIZE

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

Removal

1. Disconnect battery earth lead.
2. Remove engine acoustic cover. See «ACOUSTIC COVER - ENGINE»(ref-158804-S20286524212005013100000).
3. Remove cap from Schrader valve on fuel rail.
4. Fit LRT-19-006 and hose to Schrader valve. (Scheme 12)
5. Open valve on LRT-19-006. Release fuel system pressure and allow fuel to drain into suitable container.

Scheme 12

Installation

1. Close valve on LRT-19-006.
2. Remove hose from LRT-19-006.
3. Remove tool LRT-19-006 from Schrader valve.
4. Fit cap to Schrader valve on fuel rail.
5. Remove container.
6. Dispose of fuel and clean container.
7. Fit engine acoustic cover. See «ACOUSTIC COVER - ENGINE»(ref-158804-S20286524212005013100000) .
8. Connect battery earth lead.

FUEL SYSTEM - PRESSURE TEST

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See GENERAL INFORMATION, ELECTRICAL PRECAUTIONS .

Check

1. Disconnect battery earth lead.
2. Remove engine acoustic cover. See «ACOUSTIC COVER - ENGINE»(ref-158804-S20286524212005013100000).
3. Fit LRT-19-004 to LRT-19-006.
4. Remove Schrader valve cap.
5. Fit LRT-19-006 and LRT-19-004 to Schrader valve. (Scheme 13)
6. Open valve on LRT-19-006.
7. Connect battery earth lead.
8. Start engine and allow engine to idle.
9. Note fuel pressure gauge reading. Fuel pressure should be between 3.25-3.75 bar (47.1-54.4 psi).
10. Switch off engine.
11. Disconnect battery earth lead.
12. Close valve on LRT-19-006.
13. Position absorbent cloth around Schrader valve to collect any fuel spillage.
14. Remove LRT-19-004 and LRT-19-006 from Schrader valve.
15. Fit cap to Schrader valve.
16. Remove LRT-19-004 from LRT-19-006.
17. Fit engine acoustic cover. See «ACOUSTIC COVER - ENGINE»(ref-158804-S20286524212005013100000).
18. Connect battery earth lead.

Scheme 13

TANK - DRAIN

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See GENERAL INFORMATION, ELECTRICAL PRECAUTIONS .

Drain

1. Open fuel filler flap and remove cap. WARNING: Fuel vapor is highly 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.
2. Connect fuel recovery appliance earth lead to vehicle. WARNING: Fuel must not be extracted or drained from any vehicle while it is over a pit. Extraction or draining of fuel must be carried out in a well ventilated area.
3. Fit fuel recovery appliance extraction hose, insert hose through filler neck, turning hose slightly. If necessary, Chamfer end of bowser hose to approximately 30° to aid entry.
4. Connect exhaust extractor to tail pipes.
5. Start engine.
6. Using a fuel recovery appliance, drain the fuel from the tank into a sealed container. Follow the manufacturers instructions for the connection and safe use of the appliance.
7. Stop engine when fuel warning light is displayed. CAUTION: DO NOT allow fuel pump to run dry.
8. Disconnect battery earth lead.
9. Remove fuel tank LH module cover.
10. Remove extraction hose from filler neck and refit fuel cap.
11. Position extraction hose through aperture in fuel tank LH access hole and drain remaining fuel, number 1 in illustration. (Scheme 14) Repeat process in RH chamber draining remaining fuel, number 2 in illustration.
12. Remove extraction hose from fuel tank, disconnect earth lead from vehicle.

Scheme 14

Refill

1. Fit fuel tank LH module cover.
2. Replenish fuel as required.
3. Connect battery earth lead.
4. Turn ignition key to position 1, allow time for fuel pump to prime.
5. Start engine.
6. Stop engine and disconnect exhaust extractors.

FILTER - MAIN

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Depressurize fuel system. See «FUEL SYSTEM - DEPRESSURIZE»(/land-rover/range-rover/l322-2002-2005/remont/fuel-system/#fuel-delivery-system__fuel-system-depressurize). 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.
4. Remove 2 screws securing fuel filter access cover and remove fuel filter access cover. (Scheme 15)
5. Remove 2 screws securing fuel filter and release fuel filter from mounting brackets. (Scheme 16)
6. Position container to catch fuel spillage. Before disconnecting or removing components, ensure the immediate area around joint faces and connections are clean. Plug open connections to prevent contamination.
7. Disconnect 4 fuel hoses and remove fuel filter. (Scheme 17) WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion. Care must be taken when releasing connections. Push the fuel pipe towards the fuel filter, press the Red sleeve in the opposite direction against the pipe. When fully compressed disconnect the fuel pipe from the fuel filter. Suitable eye protection must be worn.

Scheme 15

Scheme 16

Scheme 17

1. Connect fuel hoses to fuel filter.
2. Position fuel filter to mounting brackets and secure with screws.
3. Connect battery earth lead.
4. Start and run engine to check for leaks from fuel filter and hoses.
5. Remove container.
6. Fit fuel filter access cover and secure with screws.

VAPOR SEPARATOR

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Remove fuel tank. See «PUMP - FUEL TANK»(/land-rover/range-rover/l322-2002-2005/remont/fuel-system/#fuel-delivery-system__pump-fuel-tank).
4. Release fuel tank breather hose and charcoal canister vent pipe from securing clips on fuel tank. (Scheme 18)
5. Release 2 clips and disconnect 2 hoses from fuel tank. Remove 2 scrivets and remove vapor separator. (Scheme 19)

Scheme 18

Scheme 19

1. Fit vapor separator to fuel tank and secure with 2 scrivets, connect 2 hoses to fuel tank and secure with clips.
2. Fit fuel tank breather hose and fuel tank vent pipes to fuel tank, secure with clips.
3. Fit fuel tank. See «PUMP - FUEL TANK»(/land-rover/range-rover/l322-2002-2005/remont/fuel-system/#fuel-delivery-system__pump-fuel-tank) .
4. Connect battery earth lead.

PUMP - FUEL TANK

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Drain fuel tank. See «TANK - DRAIN»(/land-rover/range-rover/l322-2002-2005/remont/fuel-system/#fuel-delivery-system__tank-drain).
2. Disconnect battery earth lead. CAUTION: Before disconnecting the battery, ensure that the key is removed from the ignition. Failure to remove the key will result in the fuel gauge memorizing its needle position before disconnection and reverting to it on reconnection of the battery.
3. Remove 4 nuts and remove fuel tank RH access cover. (Scheme 20) WARNING: Fuel vapor is highly 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.
4. Disconnect multiplug from fuel pump. (Scheme 21)
5. Position container to collect spillage. WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.
6. Noting fitted position, release fuel feed and return pipes from pump. CAUTION: Before disconnecting or removing components, ensure the immediate area around joint faces and connections are clean. Plug open connections to prevent contamination.
7. Collect fuel pipes, tie aside to aid pump removal.
8. Through tank LH aperture, release clip and disconnect combined multiplug and fuel pipe connection from fuel pump body. (Scheme 22)
9. Clean area surrounding locking ring.
10. Using tool LRT-19-009 remove locking ring from fuel tank. (Scheme 23)
11. Carefully release fuel pump tank unit assembly. Remove and discard seal.
12. Position container to collect spillage.
13. Release tank LH sensor from mounting and remove.

Scheme 20

Scheme 21

Scheme 22

Scheme 23

1. Clean area surrounding fuel tank access.
2. Clean pump body and fit new tank seal to pump.
3. Connect combined fuel pipe and multiplug from tank LH sender to pump assembly. CAUTION: Ensure clip is securely located after connection.
4. Carefully fit pump and check seal is correctly seated. From LH aperture, check foot of pump to ensure correct alignment with tank.
5. Using LRT-19-009, fit locking ring and tighten to 35 Nm (26 ft. lbs).
6. Connect fuel pipes to pump.
7. Remove container.
8. Connect multiplug to fuel pump.
9. Position fuel tank RH access panel, fit nuts and tighten to 10 Nm (7 ft. lbs).
10. Connect battery earth lead.
11. Refill fuel tank. See «TANK - DRAIN»(/land-rover/range-rover/l322-2002-2005/remont/fuel-system/#fuel-delivery-system__tank-drain) .
12. Connect TestBook/T4, to ensure new fuel level senders are working correctly, and reset adaptions.

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead.
2. Drain fuel tank. See «TANK - DRAIN»(/land-rover/range-rover/l322-2002-2005/remont/fuel-system/#fuel-delivery-system__tank-drain). WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.
3. Remove 4 nuts and remove fuel tank RH access cover. (Scheme 20)
4. Disconnect multiplug from fuel pump. (Scheme 21)
5. Remove center console. See «76.25.01 CENTER CONSOLE»(/land-rover/range-rover/l322-2002-2005/remont/exteriorinterior-trim/#interior-fittings).
6. Release cable securing clip from handbrake compensator, release handbrake cables from compensator and remove securing clip. (Scheme 24)
7. Remove rear propeller (drive) shaft. See «REAR DRIVE SHAFT»(/land-rover/range-rover/l322-2002-2005/remont/driveshaft-universal-joints/#driveshafts-universal-joints).
8. Withdraw handbrake cables from body and move aside for access.
9. Remove RH rear wheel arch liner. See «76.10.49 LINER -- REAR WHEEL ARCH -- SINGLE»(ref-208059-S38337152322005120200000).
10. Release clip from breather hose and disconnect breather hose from filler neck. (Scheme 25) WARNING: Fuel vapor is highly 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.
11. Release fuel tank breather and charcoal canister vent pipes from clip on filler neck. (Scheme 26)
12. Remove clip from breather hose and vent pipe.
13. Remove 16 bolts and 4 nuts securing fuel tank shields. (Scheme 27)
14. Disconnect 3 pipes from charcoal canister, remove 2 Torx bolts and remove charcoal canister. (Scheme 28)
15. Loosen 4 bolts securing rear sub-frame to allow removal of tank shields. (Scheme 29)
16. Collect fuel tank shields.
17. Disconnect fuel tank filler hose from fuel tank filler neck. (Scheme 30)
18. Remove 2 screws securing fuel filter and release fuel filter from mounting brackets. (Scheme 31)
19. Position container to catch fuel spillage.
20. Disconnect 3 fuel hoses and 1 reference pipe, remove fuel filter. (Scheme 32) WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.
21. Remove container.
22. With assistance remove 5 bolts securing fuel tank to body, lower and remove tank. (Scheme 33) NOTE: Pull vent and breather hoses through body while lowering fuel tank. NOTE: DO NOT carry out further dismantling if component is removed for access only.
23. Release fuel tank breather hose and charcoal canister vent pipe from securing clips on fuel tank. (Scheme 34)
24. Release 2 clips and disconnect 2 hoses from fuel tank. Remove 2 scrivets and remove vapor separator. (Scheme 19)
25. Remove charcoal canister to charcoal canister purge solenoid feed pipe from fuel tank.
26. Remove 4 scrivets securing straps to fuel tank. Collect straps.

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

1. Position straps to fuel tank and secure with scrivets.
2. Fit charcoal canister to charcoal canister purge solenoid feed pipe to fuel tank.
3. Fit vapor separator to fuel tank and secure with 2 scrivets, connect 2 hoses to fuel tank and secure with clips.
4. Fit fuel tank breather pipes and charcoal canister vent pipes to clip on fuel tank filler neck.
5. Position tank assembly and breather pipes to vehicle.
6. With assistance, fit bolts securing fuel tank to body and tighten to 45 Nm (33 ft. lbs). NOTE: Pass vent and breather hoses through body while fitting tank.
7. Connect fuel hoses to fuel filter.
8. Position fuel filter to mounting brackets and secure with screws.
9. Fit fuel tank shields, but do not fit nuts and bolts.
10. Connect breather hose to filler neck, fit and secure clip.
11. Position fuel tank vent pipe to filler neck.
12. Connect fuel tank filler hose to fuel tank filler neck.
13. Tighten bolts securing subframe to body to 165 Nm (129 ft. lbs).
14. Fit charcoal canister, tighten 2 bolts and connect 3 pipes to charcoal canister.
15. Fit bolts and nuts securing fuel tank shields and tighten to 25 Nm (18 ft. lbs).
16. Fit fuel tank breather hose to fuel tank filler neck and secure with clip.
17. Fit fuel tank breather pipes and charcoal canister vent pipes to clip on fuel tank filler neck.
18. Fit securing clip to fuel tank breather hose and charcoal canister vent pipe.
19. Fit RH rear wheel arch liner. See «76.10.49 LINER -- REAR WHEEL ARCH -- SINGLE»(ref-208059-S38337152322005120200000) .
20. Insert handbrake cables through body.
21. Fit rear propeller shaft. See «REAR DRIVE SHAFT»(/land-rover/range-rover/l322-2002-2005/remont/driveshaft-universal-joints/#driveshafts-universal-joints) .
22. Fit handbrake cable retaining clip.
23. Fit handbrake cables to compensator.
24. Fit cable retaining clip to handbrake compensator.
25. Fit center console. See «76.25.01 CENTER CONSOLE»(/land-rover/range-rover/l322-2002-2005/remont/exteriorinterior-trim/#interior-fittings) .
26. Connect multiplug to fuel pump.
27. Fit RH fuel tank access cover and secure with 4 nuts.
28. Fill fuel tank with extracted fuel. See «TANK - DRAIN»(/land-rover/range-rover/l322-2002-2005/remont/fuel-system/#fuel-delivery-system__tank-drain) .
29. Connect battery earth lead.

FILLER NECK

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Drain fuel tank. See «TANK - DRAIN»(/land-rover/range-rover/l322-2002-2005/remont/fuel-system/#fuel-delivery-system__tank-drain). WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.
4. Remove propeller shaft. See «REAR DRIVE SHAFT»(/land-rover/range-rover/l322-2002-2005/remont/driveshaft-universal-joints/#driveshafts-universal-joints).
5. Remove RH rear wheel arch liner. See «76.10.49 LINER -- REAR WHEEL ARCH -- SINGLE»(ref-208059-S38337152322005120200000).
6. Remove 8 bolts and 2 nuts securing RH fuel tank shield. (Scheme 35)
7. Release fuel tank breather pipes and charcoal canister vent pipes from clip on filler neck. WARNING: Fuel vapor is highly 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. (Scheme 26)
8. Remove clip from fuel tank breather pipe and charcoal canister vent pipe.
9. Position container to catch fuel spillage.
10. Disconnect fuel tank filler hose from fuel tank filler neck. (Scheme 30)
11. Remove container.
12. Dispose of fuel and clean container.
13. Cut 3 cable ties securing air suspension pipes to fuel tank filler neck. (Scheme 36)
14. Remove 2 nuts securing fuel tank filler neck to body, disconnect breather hose and remove fuel tank filler neck. (Scheme 37)

Scheme 35

Scheme 36

Scheme 37

1. Fit 2 nuts securing fuel tank filler neck to body, connect breather hose to fuel tank filler neck and secure with clip.
2. Fit 3 cable ties securing air suspension pipes to fuel tank filler neck.
3. Connect fuel tank filler hose to fuel tank filler neck.
4. Fit securing clip to fuel tank breather hose and charcoal canister vent pipe.
5. Fit fuel tank breather pipes and charcoal canister vent pipes to clip on fuel tank filler neck.
6. Fit bolts and nuts securing RH fuel tank shield and tighten to 25 Nm (18 ft. lbs).
7. Fit RH rear wheel arch liner. See «76.10.49 LINER -- REAR WHEEL ARCH -- SINGLE»(ref-208059-S38337152322005120200000) .
8. Fit propeller shaft. See «REAR DRIVE SHAFT»(/land-rover/range-rover/l322-2002-2005/remont/driveshaft-universal-joints/#driveshafts-universal-joints) .
9. Refill fuel tank with extracted fuel. See «TANK - DRAIN»(/land-rover/range-rover/l322-2002-2005/remont/fuel-system/#fuel-delivery-system__tank-drain) .
10. Connect battery earth lead.

COVER - TANK MODULE - LH

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See ELECTRICAL PRECAUTIONS .

1. Disconnect battery earth lead. WARNING: Fuel vapor is highly 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.
2. Remove "D" post trim casing. See «76.13.31 TRIM FINISHER -- 'D' POST -- LOWER»(/land-rover/range-rover/l322-2002-2005/remont/exteriorinterior-trim/#interior-fittings).
3. Remove opposite "D" post trim.
4. Remove 2 Allen bolts securing spare wheel removal straps to cross member and move straps aside.
5. Release carpet, fold forward and tie aside.
6. Remove 4 nuts and remove fuel tank LH access cover. (Scheme 38)
7. Clean area surrounding locking ring.
8. Using tool LRT-19-009, remove locking ring from fuel tank. (Scheme 39) CAUTION: Before disconnecting or removing components, ensure the immediate area around joint faces and connections are clean. Plug open connections to prevent contamination.
9. Remove access plug and discard fuel tank seal.

Scheme 38

Scheme 39

1. Clean area surrounding fuel tank access.
2. Clean fuel tank access plug and fit new tank seal.
3. Position fuel tank access plug, align timing and push fully home. Ensure seal is correctly fitted.
4. Using LRT-19-009, fit locking ring and tighten to 35 Nm (26 ft. lbs).
5. Fit carpet.
6. Position spare wheel release straps fit bolts and tighten to 25 Nm (18 ft. lbs).
7. Fit "D" post trim casings. See «76.13.31 TRIM FINISHER -- 'D' POST -- LOWER»(/land-rover/range-rover/l322-2002-2005/remont/exteriorinterior-trim/#interior-fittings) .
8. Connect battery earth lead.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• ELECTRICAL PRECAUTIONS
• 76.25.01 CENTER CONSOLE
• REAR DRIVE SHAFT
• FUEL SYSTEM - DEPRESSURIZE
• PUMP - FUEL TANK
• TANK - DRAIN