1995 LAND ROVER DISCOVERY Workshop Manual

19FUEL SYSTEM
22
REPAIRADD: 09/95
12.Mark location of anti-roll [sway] bar straps.
13.Remove nuts and bolts securing anti-roll [sway]
bar straps, and allow bar to swing down clear of
tank.14.Disconnect pressure sensor breather pipe
connection.
15.Disconnect vent line quickfit connector from
liquid/vapour separator.
16.Remove torque screw cap from hose to tank
filler neck clip.
17.Loosen clip screw securing hose to tank filler
neck.
18.Release hose from filler neck and internal filler
neck breather hose from fuel tank.
19.Remove and discard fuel filler neck clip.

SFI
23
REPAIR ADD: 09/95
20.Remove nut and bolt securing RH side of upper
fuel tank strap to chassis.
21.Remove 4 nuts and bolts securing fuel tank
cradle.
22.Remove fuel tank cradle.
23.With assistance, tilt right hand side of tank
upwards and manoeuvre through chassis to
remove.
Do not carry out further dismantling if
component is removed for access only.
24.Release vent hose from tank pressure sensor.
25.Remove vent hose from 3 fuel tank clips.
26.Using service tool LRT-19-009 loosen and
remove the metal locking ring.
27.Prise the pump from the tank opening using a
blunt instrument under the edge of the lip of the
pump flange.
CAUTION: Do not lift the pump from the
tank using the feed and return stubs.
28.Remove and discard seal.

19FUEL SYSTEM
24
REPAIRADD: 09/95 Refit
29.Fit NEW pump seal to tank opening.
30.Carefully lower pump into tank opening, pressing
firmly on the pump top flange to allow correct
positioning.
NOTE: Ensure location tag on pump top
flange is engaged correctly to tank
opening lip.
31.Fit locking ring and tighten to
35 Nmusing
service tool LRT-19-009.
32.Fit vent hose to fuel tank clips and connect to
pressure sensor.
33.With assistance, fit fuel tank into position.
34.Fit fuel tank cradle and secure with nuts and
bolts.
35.Align upper fuel tank strap and secure with nut
and bolt.
36.Fit NEW clip to fuel filler neck hose.
37.Connect fuel filler neck internal breather to tank.
38.Connect fuel filler neck hose to tank.
39.Position fuel filler neck hose clip and tighten until
head shears.
40.Connect vent line quickfit connector to
liquid/vapour separator.
41.Connect vent line hose connection.
42.Position anti-roll [sway] bar straps and secure
with nuts and bolts.
43.Remove stand(s) and lower vehicle.
44.Connect both fuel lines to the pump by pushing
the connectors down each line square to the
pump connection until the connectors positively
latches.
45.Connect multiplugs to fuel pump and pressure
sensor.
46.Reconnect battery negative lead.
47.Refill tank with drained fuel.
48.Run the engine to check for any fuel leaks.
49.Fit access panel and secure with screws.
50.Reposition loadspace sound insulation and
carpet.
51.Fit RH luggage compartment side panel.
See
CHASSIS AND BODY, Repair, rear
compartment trim panels
52.Fit tail door tread strip and secure with screws.FUEL TANK - DRAINING - ADVANCED EVAPS
Service repair no - 19.55.02
WARNING: Before removing the fuel tank
it must be drained.
WARNING: Petrol/gasoline vapour 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. See Introduction
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.
NOTE: Assuming the fuel tank is FULL
drain the following quantities:
Renew Fuel pump = 9 Litres (2.4 US Gallons)
Renew Fuel filler neck = 22 Litres (6 US Gallons)
Renew Fuel tank = COMPLETE DRAIN
1.Depressurise fuel system.
See fuel system -
depressurise - advanced evaps
2.Disconnect battery negative lead.
3.Remove 6 screws securing tail door tread strip
and remove tread strip.
4.Remove RH luggage compartment side panel.
See CHASSIS AND BODY, Repair,

SFI
25
REPAIR ADD: 09/95
5.Fold back loadspace carpet and sound
insulation to reveal access panel.
6.Remove 6 screws securing fuel pump access
panel.
7.Remove access panel.
8.Disconnect the fuel return connection by
pressing the black release latch on connector
and pushing the connector back down the line.
Care must be taken to catch any excess fuel
which may spill from the fuel line once removed.
9.Using a bowser, with a 7 mm inside diameter
hose connection attach to fuel pump return stub,
drain fuel into a sealed container. Follow the
manufacturers instructions for the connection
and safe use of the bowser.
10.Continue draining until air bubbles appear and
fuel ceases to flow.
11.Disconnect bowser from fuel pump return stub.
12.Connect fuel return line to pump by pushing the
connector down line square to the pump
connection until the connector positively latches.
13.Fit access panel and secure with screws.
14.Reposition loadspace sound insulation and
carpet.
15.Fit RH luggage compartment side panel.
See
CHASSIS AND BODY, Repair, rear
compartment trim panels
16.Fit tail door tread strip and secure with screws.
17.Reconnect battery negative lead.

19FUEL SYSTEM
26
REPAIRADD: 09/95 FUEL FILLER NECK - ADVANCED EVAPS
Service repair no - 19.55.07
WARNING: Ensure that fuel handling
precautions given in 1 - 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.
Remove
1.Depressurise fuel system.
See fuel system -
depressurise - advanced evaps
2.Disconnect battery negative lead.
3.Check the amount of fuel in the tank. If the tank
is full drain 6 US gallons (22 litres) minimum.
See fuel tank - draining.
4.Remove 6 screws securing tail door tread strip
and remove tread strip.
5.Remove RH luggage compartment side panel.
See CHASSIS AND BODY, Repair, rear
compartment trim panels
6.Fold back loadspace carpet and sound
insulation to gain access to RH mudflap fixing.
7.Raise rear of vehicle.
WARNING: Support on safety stands.
8.Remove nut and bolt securing filler neck support
bracket to mud flap bracket.
NOTE: This fixing also retains the filler
neck earth strap.
9.Remove 5 nuts and bolts securing mud flap to
body.
10.Remove mud flap.

SFI
27
REPAIR ADD: 09/95
11.Disconnect vent line quickfit connector from
liquid/vapour separator.
12.Remove torque screw cap from hose to tank
filler neck clip.
13.Loosen clip screw securing hose to tank filler
neck.
14.Release hose from filler neck and internal filler
neck breather hose from fuel tank.
15.Remove and discard fuel filler neck clip.
16.Disconnect the pressure sensor breather pipe
connection.
17.Disconnect the vent line hose connection.
18.Fit ignition key to fuel filler flap lock and open
flap.
19.Release fuel filler cap from filler neck.
20.Remove filler neck assembly from vehicle.
Do not carry out further dismantling if
component is removed for access only.
21.Remove torque screw cap from hose to filler
neck clip.
22.Loosen clip screw securing hose to filler neck.
23.Remove hose from filler neck.
24.Remove and discard fuel filler hose clip.
25.Remove vent line from filler neck.

19FUEL SYSTEM
28
REPAIRADD: 09/95 Refit
26.Fit vent line to filler neck.
27.Fit NEW clip to filler neck hose.
28.Fit hose to filler neck.
29.Position filler neck hose clip and tighten until
head shears.
30.Fit filler neck assembly to vehicle.
NOTE: To aid fitment of filler neck through
body grommet apply a soap solution to lip
of grommet.
31.Fit NEW clip to fuel filler neck hose.
32.Connect fuel filler neck internal breather to tank.
33.Connect fuel filler neck hose to tank.
34.Position fuel filler neck hose clip and tighten until
head shears.
35.Connect vent line quickfit connector to
liquid/vapour separator.
36.Connect the pressure sensor breather pipe
connection.
37.Connect the vent line hose connection.
38.Fit mud flap and secure with nuts and bolts.
39.Position filler neck support bracket and earth
strap to mud flap bracket and secure with nut
and bolt.
40.Remove stand(s) and lower vehicle.
41.Reposition loadspace sound insulation and
carpet.
42.Fit RH luggage compartment side panel.
See
CHASSIS AND BODY, Repair,
43.Fit tail door tread strip and secure with screws.
44.Refill tank with drained fuel.
45.Fit fuel filler cap to filler neck.
46.Close filler flap, lock with ignition key and
remove key.
47.Reconnect battery negative lead.FUEL TANK FILLER CAP - ADVANCED EVAPS
Service repair no - 19.55.08
Remove
1.Fit ignition key to fuel filler flap lock and open
flap.
2.Remove screw securing cap retaining strap to
body.
3.Remove fuel filler cap.
Refit
4.Fit fuel filler cap.
5.Position cap retaining strap to body and secure
with screw.
6.Close filler flap, lock with ignition key and
remove key.

SFI
29
REPAIR ADD: 09/95 ANTI-TRICKLE FILL VALVE - ADVANCED EVAPS
Service repair no - 19.55.31
Remove
1.Remove the fuel filler neck.
See fuel filler neck
- advanced evaps
2.Release the cobra clip securing the hose to the
liquid/vapour separator and disconnect the hose.
3.Loosen the grub screw on the valve nut, two
complete turns.
4.Loosen the valve nut completely.
NOTE: The nut is held captive by the stub
pipe on the filler neck.
5.Carefully remove the valve and hose assembly
from the filler neckRefit
6.Fit a new 'O' ring to the recess in the stub pipe.
7.Fit the valve and hose assembly to the filler neck
stub pipe, ensuring that the 'O' ring is fitted
around the body of the valve as it is pushed into
the filler neck stub pipe.
8.Hand tighten the nut, then tighten to
3 Nm.
9.Tighten the grub screw to2 Nm.
10.Connect the hose to the liquid/vapour separator
and secure with the cobra clip.
11.Fit the fuel filler neck.
See fuel filler neck -
advanced evaps;refit