Published: 11-May-2011

2007.0 Range Rover Sport (LS), 310-01D

Fuel Tank and Lines - TDV8 3.6L Diesel

Fuel Tank (G952619)

REMOVAL AND INSTALLATION
  • 19.55.01
  • Fuel Tank - Renew
  • TDV8
  • 1.70
  • USED WITHINS
Removal
WARNINGS:

  • Place the vehicle in a well ventilated, quarantined area and arrange ' No Smoking/Petrol Fumes' signs about the vehicle.

  • Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

  • Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

  • The spilling of fuel is unavoidable during this operation. Make sure that all necessary precautions are taken to prevent fire and explosion.

CAUTION:

Before disconnecting or removing components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.


The following step(s) applies to:
All vehicles

  1. Disconnect the battery ground cable. For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).
  2. Drain the fuel tank. For additional information, refer to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).
  3. WARNING:

    Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

    Raise and support the vehicle.
  4. E44306
    Remove the fuel tank heat shield.
      • Remove the 3 bolts.
      • Remove the 2 nuts.
  5. CAUTION:

    Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

    E51525
    Disconnect the fuel filler neck from the fuel tank.
      • Remove the tamper proof cover.
      • Remove and discard the hose clip.
  6. WARNING:

    Secure the component to the transmission jack.

    E51522
    Using a transmission jack, lower the fuel tank.
      • Remove the 6 bolts.
  7. NOTE:

    Note the fitted position.

    E51523
    Release the fuel tank vent and fuel lines.
      • Remove the retainers.
      • Release from the clips.
      • Remove the adhesive pad.
  8. CAUTION:

    Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

    Disconnect the fuel tank vent lines.
      • Release the clip.

The following step(s) applies to:
Vehicles with fuel fired heater

  1. Release the fuel fired booster heater fuel line.
      • Release from the 2 clips.

The following step(s) applies to:
Vehicles with fuel fired heater

  1. CAUTION:

    Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

    Disconnect the fuel fired booster heater fuel line.
      • Release the clip.

The following step(s) applies to:
All vehicles

  1. CAUTION:

    Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

    Disconnect the 2 fuel lines.
      • Release the 2 clips.
  2. Disconnect the fuel pump module electrical connector.
  3. E51518
    Remove the fuel tank.
  4. NOTE:

    Do not disassemble further if the component is removed for access only.

    With assistance, remove the fuel tank from the transmission jack.
  5. CAUTION:

    Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

    NOTE:

    Note the fitted position.

    E51519
    Release the fuel pump module access flange.
      • Loosen the screw.
      • Remove the clamp.
  6. CAUTION:

    Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

    E51526
    Remove the fuel pump module access flange.
      • Disconnect the vent line.
      • Disconnect the fuel supply line.
      • Disconnect the 3 electrical connectors.
      • Remove and discard the seal.
  7. E51520
    Remove the fuel pump module.
      • Release the strap.
      • Release the fuel pressure regulator.
      • Disconnect the 2 fuel lines.
  8. E51528
    Remove the fuel tank front fuel level sender unit.
      • Release the lead.
      • Release the clip.
  9. E51529
    Remove the fuel tank bracket.
      • Remove the 2 clips.
      • Remove the 2 bolts.
      • Remove the retaining plate.
Installation

The following step(s) applies to:
All vehicles

  1. Install the fuel tank bracket.
      • Install the retaining plate.
      • Install the clips.
      • Tighten the bolts to 10 Nm (7 lb.ft).
  2. Install the fuel tank front fuel level sender unit.
      • Secure the clip.
      • Secure the lead.
  3. Install the fuel pump module.
      • Connect the fuel lines.
      • Secure with the strap.
      • Secure the fuel pressure regulator.
  4. Install the fuel pump module access flange.
      • Clean the component mating faces.
      • Install a new seal.
      • Connect the 3 electrical connectors.
      • Connect the fuel supply line.
      • Connect the vent line.
  5. CAUTION:

    Make sure the seal is installed correctly.

    NOTE:

    Align to the position noted on removal.

    Secure the fuel pump module access flange.
      • Install the clamp.
      • Tighten the screw to 4 Nm (3 lb.ft).
  6. With assistance, install the fuel tank to the transmission jack.
  7. Position the fuel tank to the vehicle.
  8. Connect the fuel lines.
      • Secure with the clip.

The following step(s) applies to:
Vehicles with fuel fired heater

  1. Connect the fuel fired booster heater fuel line.
      • Secure with the clip.
  2. Connect the vent lines.
      • Secure with the clip.
  3. Connect the electrical connector.
  4. Secure the fuel and vent lines.
      • Secure in the clips.
      • Install the retainers.
      • Install the adhesive pad.
  5. Install the fuel tank.
      • Tighten the bolts to 45 Nm (33 lb.ft).
  6. CAUTION:

    Tighten the new tamper proof clip until the hexagon shears.

    Connect the fuel filler neck.
      • Install a new retaining clip.
  7. Install the fuel tank heat shield.
      • Tighten the bolts to 6 Nm (4 lb.ft).
      • Tighten the nuts to 3 Nm (2 lb.ft).
  8. Refill the fuel tank. For additional information, refer to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).