Fuel System - Fuel Tank Availability/Installation
No: LTB00293Issue: 1
Date: 16 JUNE 2010
SECTION: 310
Fuel Tank Availability / Installation
AFFECTED VEHICLE RANGE:
CONDITION SUMMARY:
Situation:
The fuel tank for 2005 - 2009 model year LR3 and 2006 - 2009 model year Range Rover Sport vehicles has been updated.
Action:
In the event it is necessary to install a complete fuel tank, refer to the appropriate Replacement Procedure outlined below to install an updated fuel tank and any other associated components as indicated.
PARTS:
TOOLS:
Refer to Workshop Manual (GTR) for any required special tools
WARRANTY:
NOTE:
Repair procedures are under constant review, and therefore times are subject to change; those quoted here must be taken as guidance only. Always refer to DDW to obtain the latest repair time.
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policies and procedures apply.
REPLACEMENT PROCEDURE - LR3 ONLY
REMOVE FUEL TANK AND FILLER NECK
NOTE:
Global Technical Reference (GTR) lookup sequence is as follows:
GTR Home > NAS > LA - LR3 > Service Information > Model Year > Workshop Manual
1. Refer to Workshop Manual (GTR) section 310-01A, Fuel Tank and Lines - 40L NA V6, or 310-01B, Fuel Tank and Lines - 4.4L V8-AJ41, and remove the fuel tank [19.55.01] and fuel tank filler pipe [19.55.07].
INSTALL NEW FUEL TANK AND FILLER NECK
1. Ensure the foam pad is correctly installed. (Figure 1)
2. Install the link lead harness (LR020971) onto the new fuel tank (LR021524 [Figure 2]):
^ Attach the two electrical connectors to the clips
^ Secure with a suitable cable tie
3. Refer to Workshop Manual (GTR) section 310-01A, Fuel Tank and Lines - 4.0L NA V6, or 310-01B, Fuel Tank and Lines - 4.4L V8-AJ41, and install the new fuel tank filler pipe (LR013825) [19.55.07] and the fuel tank [19.55.01].
REPLACEMENT PROCEDURE - RANGE ROVER SPORT 4.4L NA V8 ONLY
REMOVE FUEL TANK, FUEL LINE, FUEL PUMP MODULE, AND FILLER NECK
NOTE:
Global Technical Reference (GTR) lookup sequence is as follows:
GTR Home > NAS > LS - Range Rover Sport > Service Information > Model Year > Workshop Manual
1. Refer to Workshop Manual (GTR) section 310-01B, Fuel Tank and Lines - 4.4L NA V8-AJ41, and remove the
2. Remove and discard the fuel line. (Figure 3)
3. Refer to Workshop Manual (GTR) section 310-01B, Fuel Tank and Lines - 4.4L V8-AJ41, and remove the fuel pump module [19.45.03] from the NEW fuel tank.
INSTALL NEW FUEL TANK, FUEL PUMP MODULE, FUEL LINE, AND FILLER NECK
1. Refer to Workshop Manual (GTR) section 310-01B, Fuel Tank and Lines - 4.4L V8-AJ41, and install the NEW fuel pump module (LR016845) [19.45.03] into the NEW fuel tank (LR021527).
2. Ensure the foam pad is correctly installed. (Figure 1)
3. Install the link lead harness (LR020971) onto the new fuel tank (Figure 2):
^ Attach the two electrical connectors to the clips
^ Secure with a suitable cable tie
CAUTION:
Ensure the fuel lines are correctly orientated; failure to correctly align the fuel lines may result in damage to the vehicle.
4. Install the new fuel line (LR015975) to the fuel tank: (Figure 3)
^ Remove blanking plugs.
^ Install fuel line to the fuel pump module.
5. Refer to Workshop Manual (GTR) section 310-01B, Fuel Tank and Lines - 4.4L V8-AJ41, and install the new fuel tank filler pipe (LR013825) [19.55.07] and the fuel tank [19.55.01].
REPLACEMENT PROCEDURE - RANGE ROVER SPORT 4.2L SC V8 ONLY
REMOVE FUEL TANK, FUEL LINE, AND FILLER NECK
NOTE:
Global Technical Reference (GTR) lookup sequence is as follows:
GTR Home > NAS > LS - Range Rover Sport > Service Information > Model Year > Workshop Manual
1. Refer to Workshop Manual (GTR) section 310-01A, Fuel Tank and Lines - 4.2L SC V8, and remove the fuel tank [19.55.01] and fuel tank filler pipe [19.55.07].
2. Remove and retain the fuel line retaining clip from the fuel line / fuel pump module.
3. Discard the fuel line. (Figure 3)
INSTALL NEW FUEL TANK, FUEL LINE, AND FILLER NECK
1. Ensure the foam pad is correctly installed. (Figure 1)
2. Install the link lead harness (LR020971) onto the new fuel tank (LR021527) [Figure 2]:
Attach the two electrical connectors to the clips
^ Secure with a suitable cable tie
3. Install the fuel line retaining clip into the fuel pump module. (green clip, Figure 4)
CAUTION:
Ensure the fuel lines are correctly orientated; failure to correctly align the fuel lines may result in damage to the vehicle.
4. Install the new fuel line (LR015975) to the fuel tank: (Figure 3)
^ Remove blanking plugs.
^ Install fuel line to the fuel pump module.
5. Refer to Workshop Manual (GTR) section 310-01A, Fuel Tank and Lines - 4.2L SC V8, and install the new fuel tank filler pipe (LR013825) [19.55.07] and the fuel tank [19.55.01].