1995 LAND ROVER DISCOVERY fuel tank removal

01INTRODUCTION
2
INFORMATION FUEL HANDLING PRECAUTIONS
The following information provides basic precautions
which must be observed if fuel is to be handled safely.
It also outlines the other areas of risk which must not
be ignored.
This information is issued for basic guidance only, and
in any case of doubt, appropriate enquiries should be
made of your local Fire Officer or Fire Department.
Fuel vapour is highly flammable and in confined
spaces is also very explosive and toxic.
When fuel evaporates it produces 150 times its own
volume in vapour, which when diluted with air
becomes a readily ignitable mixture. The vapour is
heavier than air and will always fall to the lowest level.
It can readily be distributed throughout a workshop by
air current, consequently, even a small spillage of fuel
is very dangerous.
Always have a fire extinguisher containingFOAM CO
2
GAS,orPOWDERclose at hand when handling fuel,
or when dismantling fuel systems and in areas where
fuel containers are stored.
WARNING: lt is imperative that the battery
is not disconnected during fuel system
repairs as arcing at the battery terminal
could ignite fuel vapour in the atmosphere.
Always disconnect the vehicle battery BEFORE
carrying out work on the fuel system.
Whenever fuel is being handled, transferred or
stored, or when fuel systems are being dismantled
all forms of ignition must be extinguished or
removed, any leadlamps used must be flame proof
and kept clear of spillage.
No one should be permitted to repair components
associated with fuel without first having had fuel
system training.Hot fuel handling precautions
WARNING: Before commencing any
operation requiring fuel to be drained from
the fuel tank, the following procedure must
be adhered to:
1.Allow sufficient time for the fuel to cool, thus
avoiding contact with hot fuels.
2.Vent the system by removing the fuel filler cap in
a well ventilated area. Refit the filler cap until the
commencement of fuel drainage.
Fuel transfer
WARNING: Fuel must not be extracted or
drained from any vehicle while it is
standing over a pit.
The transfer of fuel from the vehicle fuel tank must be
carried out in a well ventilated area. An approved
transfer tank must be used according to the transfer
tank manufacturer's instructions and local regulations,
including attention to grounding of tanks.
Fuel tank removal
AFUEL VAPOURwarning label must be attached to
the fuel tank upon removal from the vehicle.
Fuel tank repair
Under no circumstances should a repair to any tank
be attempted.

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1
REPAIR TANK SENDER UNIT
Service repair no - 88.25.32
WARNING: Ensure that the WARNINGS
and FUEL HANDLING PRECAUTIONS
given in Section 01 are adhered to before
carrying out the following operations.
Special tool - LST131
Remove
1.Disconnect battery negative lead.
2.Remove the rear carpet retainer.
3.Ease the carpet from under the lower trim panels
at the rear of the fold down seats.
4.Raise the carpet to expose the sound insulation.
5.Fold back the sound insulation to reveal the
access panel.
6.Remove the securing screws and detach the
access panel from the floor.
7.Disconnect the multi-plug from sender unit.8.Disconnect the fuel pipes from the sender unit.
9.Using special tool LST131 remove the locking
ring and withdraw the sender unit from the fuel
tank.
Refit
10.Fit the sender unit to the fuel tank and secure
with the locking ring. Tighten to
45to50 Nm.
11.Connect the fuel pipes to the sender unit.
12.Connect multi-plug to sender unit.
13.Inspect the access panel seal to ensure that it is
satisfactory for further use, renew as necessary.
14.Fit the access panel to the aperture in the floor
and secure with the screws.
15.Reverse removal procedure. 1 to 5. Refit the
sound insulation and carpet.

19FUEL SYSTEM
20
REPAIR ACCELERATOR PEDAL
Service repair no - 18.30.35
Remove
1.Remove lower dash panel.
2.Remove clevis pin securing throttle cable to
accelerator pedal.
3.Release tension from pedal return spring.
4.Remove circlip from pedal pivot pin.
5.Withdraw pivot pin.
NOTE: It may be necessary to lower
steering column to gain access to pivot
pin circlip.
6.Remove accelerator pedal.
Refit
7.Lightly grease pivot and clevis pins.
8.Fit clevis pin using aNEWcotter pin.
9.Reverse removal procedure.FUEL PUMP AND SENDER UNIT
Service repair no - 19.45.03
A plastic fuel tank with a combined fuel pump/sender
unit is fitted. The fuel pump/sender unit is accessed
through a panel in the load space floor.
Fuel pump/sender unit
WARNING: Ensure that fuel handling
precautions given in Section 01 -
Introduction are strictly adhered to when
carrying out following instructions.
CAUTION: Before disconnecting any part
of fuel system, it is imperative that all dust,
dirt and debris is removed from around
components to prevent ingress of foreign matter
into fuel system.
Service Tools:
LRT-19-001 wrench - pump retaining ring
LRT-19-002 'Speedfit' disconnector
Remove
1.Depressurise fuel system.
See Depressurising
Fuel System
2.Disconnect battery negative lead.
3.Syphon at least 9 litres (2 gallons) of fuel from
fuel tank into a suitable container that can be
sealed.
4.Remove carpet from loadspace floor and
tailgate.
5.Fold back loadspace sound insulation to reveal
access panel.

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REPAIR 6.Remove access panel from floor.
7.Disconnect multi-plug from fuel sender unit.
8.Disconnect two fuel line unions from fuel pump.
9.Using service tool no. LRT-19-001, remove
pump unit retaining ring. Withdraw unit from fuel
tank.
WARNING: A quantity of fuel will be
retained in body of unit, care must be
taken to prevent fuel spillage when unit is
removed.
Refit
10.Insert fuel pump into tank. Fit retaining ring.
Tighten to
48 Nm.
11.Connect fuel lines to pump.
12.Connect multi-plug to sender unit.
13.After assembly, check all fuel pipes, sealing
rings and hose connections are secure.
14.Run engine to check for fuel leaks.
15.Inspect access panel seal, fit a new seal if
necessary.
16.Fit access panel and tighten screws.
17.Reverse removal procedure. 4 - 5. Fit insulation
and carpet.

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REPAIR
13.Remove back two bolts and nut plates securing
fuel tank cradle.
14.Remove front nuts, bolts and washers. Remove
fuel tank cradle.
15.With assistance, tilt right hand side of tank
upwards and manoeuvre tank through chassis to
remove.
Refit
16.Reverse removal procedure. Ensuring sealing
ring, fuel pipe and hose connections are secure.
17.Run engine, check all connections for fuel leaks.