Land Rover Defender: Fuel Tank - Ingenium I4 2.0l Petrol, 90

REMOVAL AND INSTALLATION

REMOVAL

WARNING:

• Make sure the fuel tank is suitably supported at all times.
• Be prepared to collect escaping fuel.

CAUTION: Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all openings must be sealed.

NOTE:

• This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
• This procedure contains illustrations showing certain components removed to provide extra clarity.

The following step(s) applies to: All vehicles

1. Before working on the fuel system make sure to study the fuel system health and safety section of this manual.

2. Raise and support the vehicle on a suitable 2 post lift.

3. Disconnect the startup battery ground cable.

4. Drain the fuel tank.

5. Remove the rear driveshaft.

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

6.

Disconnect the Fuel Fired Booster Heater (FFBH) line connector.

The following step(s) applies to: All vehicles

7.

• Disconnect the fuel tank line.
• Release the fuel line from the clip.

8.

• Remove the 6 nuts.
• Remove the 2 rear body braces.

9.

WARNING: This step requires the aid of another technician.

• Release the fuel tank filler pipe clip.
• Release the fuel tank filler pipe from the fuel tank.
• Remove the 7 bolts.
• Remove the fuel tank.

10.

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

• Disconnect the fuel line.
• Release the fuel line from the 5 clips.
• Remove the fuel line.

11.

• Remove the 4 bolts.
• Remove the fuel tank heatshield

12.

• Reposition the fuel pump module to get access to the electrical connector.
• Disconnect the electrical connector.

13.

• Disconnect the fuel line from the fuel pump.
• Remove the fuel pump.

INSTALLATION

The following step(s) applies to: All vehicles

1.

NOTE: Steps 1-3 are only required if previously removed.

• Install the fuel pump.
• Connect the fuel line to the fuel pump.
• Connect the electrical connector.

2.

• Install the fuel tank heatshield.
• Install and tighten the 4 bolts.

  Torque: 10Nm

3.

• Install the fuel line.
• Install the fuel line to the 5 clips.
• Connect the fuel line.

4.

WARNING: This step requires the aid of another technician.

• Install the fuel tank.
• Install and tighten the 7 bolts.

  Torque: 48Nm

• Install the fuel filler pipe to the fuel tank.
• Install and tighten the clip.

  Torque: 3.5Nm

5.

• Install the 2 rear body braces.
• Install and tighten the 6 nuts.

  Torque: 48Nm

6.

• Connect the fuel tank line.
• Install the fuel line to the clip.

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

7. Connect the FFBH line connector.

The following step(s) applies to: All vehicles

8. Install the rear driveshaft.

9. Fill the fuel tank.

10. Connect the startup battery ground cable.

11. Bleed the fuel system.

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