Page 886 of 1007

HEATING AND VENTILATION
REPAIRS 80-21
Fuel pump - fuel burning heater - from
03MY
$% 80.40.40
Remove
1.Disconnect battery earth lead.
WARNING: Fuel vapour is highly flammable
and in confined spaces is also explosive
and toxic. Always have a fire extinguisher
containing foam, CO
2, gas or powder close
at hand when handling or draining fuel.
2.Raise vehicle on lift.
3.Remove 2 bolts securing fuel pump and filter
assembly to body.
4.Lower fuel pump and filter assembly.
5.Disconnect multiplug from fuel burning heater
pump.
6.Position container below fuel pipes to collect
fuel spillage.7.Disconnect fuel pipes from fuel burning heater
pump.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
8.Release and remove fuel burning heater pump
from fuel pump and filter assembly.
Refit
1.Clean fuel pipe connections.
2.Fit and secure fuel burning heater pump to fuel
pump and filter assembly.
3.Connect fuel pipes to fuel burning heater pump.
4.Remove container from below fuel pipes.
5.Connect multiplug to fuel burning heater pump.
6.Position fuel pump and filter assembly to body,
fit bolts and tighten to 10 Nm (7 lbf.ft).
7.Lower vehicle on lift.
8.Connect battery earth lead.
M19 3624
Page 983 of 1007
HARNESSES
86-7-8 REPAIRS
74.Release all harness clips from interior of
vehicle.
75.Release and disconnect multiplugs from base
of 'B/C' posts.
76.Remove luggage compartment carpet.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.77.Remove 6 screws from fuel pump access cover
and remove cover.
78.Disconnect multiplug from fuel pump.
79.Release both rear ABS speed sensor
harnesses and disconnect multiplugs.
80.Pull harness into vehicle interior.
Page 985 of 1007

HARNESSES
86-7-10 REPAIRS
90.Remove 4 screws from rear bumper lamps,
release lamps and disconnect multiplugs.
91.Release harness clips and pull harness into
luggage compartment.
92.Release main harness retaining clips and pull
harness into vehicle interior.
93.Remove main harness.Refit
1.Lay main harness in vehicle.
2.Locate rear section and secure in retaining
clips.
3.Feed harness to rear bumper lamps, secure in
clips and grommets.
4.Connect multiplugs to rear bumper lamps, fit
rear lamps and secure with screws.
5.Fit LH rear earth header and secure with nut.
6.Connect multiplugs to LH tail lamp.
7.Position RH tail lamp and connect multiplugs.
8.Fit RH tail lamp and secure with Torx screws.
9.Fit RH rear earth header and secure with nut.
10.Connect multiplug to towing electrics.
11.Connect rear screen washer tube.
12.Connect tail door harness multiplugs.
13.Connect and fit rear window lift and wash/wipe
relays.
14.Position harness into luggage compartment.
15.Connect both rear ABS speed sensor
multiplugs and secure harness grommets.
16.Connect multiplug to fuel pump.
17.Fit fuel pump access cover and secure with
screws.
18.Fit luggage compartment carpet.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - luggage compartment.
19.Connect multiplugs at the base of 'B/C' Posts.
20.Fit all harness clips to interior of vehicle.
21.Fit multiplugs and earth header to LH lower 'A'
post.
22.Fit earth header to RH lower 'A' post.
23.Connect multiplug to window lift ECU.
24.Fit face level vent ducting.
25.Fit steering column to bracket and secure with
nuts.
26.Fit rear heater ducting and secure with nut.
27.Secure harness to rear heater ducting with
clips.
28.Position mounting bracket and secure relays.
29.Connect Lucar to handbrake switch.
30. Manual gearbox only: Connect multiplug to
gear lever hill descent switch.
31.Connect multiplug to accelerometer.
32. Automatic gearbox only: Connect multiplugs
to gear selector.
33.Connect heated oxygen sensor multiplug.
34.Fit earth header to floor tunnel and secure with
nut.
35.Fit earth lead to airbag ECU and secure with
bolt.
36.Connect multiplug to airbag ECU.
37.Connect multiplugs to brake light switch and
brake pedal position switch.
38.Connect multiplug to throttle position sensor.
39.Fit harness clip to steering column.
40.Connect multiplug to steering column switch.
Page 1005 of 1007

INSTRUMENTS
88-6 REPAIRS
Sender unit - fuel tank gauge
$% 88.25.32
Remove
1.Disconnect battery earth lead.
2.Remove fuel pump assembly.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Pump - fuel.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Pump - integral - fuel tank - rear -
up to 03MY.
WARNING: Fuel vapour is highly flammable
and in confined spaces is also explosive
and toxic. Always have a fire extinguisher
containing foam, CO
2, gas or powder close
at hand when handling or draining fuel.
3.Disconnect 2 Lucars from top of pump unit
assembly.
4.Release sprag clip securing sender to pump
unit assembly.
5.Remove sender unit.
Refit
1.Position sender to location slots and engage
sprag clip.
CAUTION: Ensure that each of the 4
location lugs on the sender are engaged
with corresponding slots in the tank unit.
2.Connect Lucars to top of pump unit assembly.
3.Fit fuel pump assembly.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Pump - fuel.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Pump - integral - fuel tank - rear -
up to 03MY.
4.Connect battery earth lead.
Sender unit assembly - fuel tank - Td4
models - from 03MY
$% 88.25.37
Remove
1.Disconnect battery earth lead.
WARNING: Fuel vapour is highly flammable
and in confined spaces is also explosive
and toxic. Always have a fire extinguisher
containing foam, CO
2, gas or powder close
at hand when handling or draining fuel.
2.If fuel tank is full, using a fuel recovery
appliance, drain excess fuel from fuel filler neck
until a level below height of fuel pump is
obtained.
3.Open RH rear and tail doors.
4.Fold RH rear seat forward.
5.Remove 3 fasteners securing front and rear
carpets.
6.Pull back carpet from fuel tank sender
assembly access panel.
M88 0356
Page 1006 of 1007

INSTRUMENTS
REPAIRS 88-7
7.Remove 6 screws securing fuel tank sender
assembly access panel to floor.
8.Remove fuel tank sender assembly access
panel.
9.Disconnect multiplug from fuel tank sender
assembly.
10.Place a container beneath fuel tank to collect
possible fuel spillage.
11.Release and remove fuel pressure relief, fuel
feed and return hoses from fuel tank sender
assembly.
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
12. Models with fuel burning heater (FBH):
Release clip and disconnect FBH fuel feed
hose from fuel tank sender assembly.
CAUTION: Always fit plugs to open
connections to prevent contamination.13.Use LRT-19-009 and remove locking ring from
fuel tank sender assembly.
14.Remove fuel tank sender assembly from fuel
tank and discard seal.
NOTE: The fuel pump and fuel gauge tank unit
are integral parts of the fuel pump housing and
cannot be renewed separately
M88 0359