Discovery 2. Manual — part 506

FUEL DELIVERY SYSTEM - TD5

REPAIRS 19-1-15

REPAIRS

Switch - inertia - fuel cut-off

$% 19.22.09

Remove

1. Disconnect multiplug from fuel cut-off switch.
2. Remove 2 screws securing fuel cut-off switch to

bulkhead.

3. Remove fuel cut-off switch from bulkhead.

Refit

1. Position fuel cut-off switch to bulkhead and

secure with screws.

2. Connect multiplug to fuel cut-off switch.
3. To set the fuel cut-off switch, depress the top of

the fuel cut-off switch.

Pump - fuel

$% 19.45.08

NOTE: The fuel pump and fuel gauge tank unit are
integral parts of the fuel pump housing and cannot be
renewed separately

Remove

1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Models with third row seats: Remove RH

third row seat.

SEATS, REPAIRS, Seat - third row.

4. Remove 5 trim clips securing lower edge of RH

'D' post trim casing.

5. Models with rear ICE controls: Remove

screw securing remote ICE controls to RH side
trim casing.

6. Models with rear ICE controls: Release ICE

controls from RH side trim casing. Disconnect
multiplug and remove ICE controls.

7. Partially remove tail door aperture seal in the

area of the RH side trim casing.

FUEL DELIVERY SYSTEM - TD5

19-1-16 REPAIRS

8. Remove 2 trim clips securing RH side trim

casing to body.

9. Remove rear lamp access panel from RH side

trim casing.

10. Remove trim clip securing RH side trim casing

to lower 'E' post.

11. Models with third row seats:Remove bolt

securing lower mounting of RH third row seat
belt to body.

12. Remove RH side trim casing.
13. Pull back loadspace carpet from fuel pump

access panel.

14. Remove 6 screws securing access panel.
15. Remove access panel.
16. Disconnect multiplug and 4 fuel hoses from fuel

pump housing.

CAUTION: Always fit plugs to open
connections to prevent contamination.

17. Use LRT-19-009 to remove locking ring from

fuel pump housing.

18. Remove fuel pump housing.
19. Remove and discard sealing ring from fuel

pump housing.

Refit

1. Clean fuel pump housing and mating face on

fuel tank.

2. Fit new seal to mating face on fuel tank.
3. Fit fuel pump housing to fuel tank and use LRT-

19-009 to fit locking ring.

4. Connect multiplug and fuel hoses to fuel pump

housing. Ensure each hose is installed in the
connector with the corresponding colour
code.

5. Fit access panel and secure with screws.
6. Reposition loadspace carpet.
7. Fit RH side trim casing.
8. Models with third row seats:Fit bolt securing

lower mounting of RH third row seat belt to
body and tighten to 50 Nm (37 lbf.ft).

9. Fit trim clip securing RH side trim casing to

lower 'E' post.

10. Fit rear lamp access panel to RH side trim

casing.

11. Fit trim clips securing RH side trim casing to

body.

12. Fit tail door aperture seal.
13. Models with rear ICE controls: Connect

multiplug to remote ICE controls.

14. Models with rear ICE controls: Fit ICE

controls to trim casing and secure with screw.

15. Fit trim clips securing lower edge of 'D' post

trim casing to body.

16. Models with third row seats: Fit RH third row

seat.

SEATS, REPAIRS, Seat - third row.

17. Connect battery earth lead.

FUEL DELIVERY SYSTEM - TD5

REPAIRS 19-1-17

Tank - fuel

$% 19.55.01

Remove

1. Drain fuel tank.

FUEL DELIVERY SYSTEM - Td5,

ADJUSTMENTS, Fuel tank - drain.

2. Raise rear of vehicle.

WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.

3. Release clips securing filler and breather hoses

and release hoses from filler neck.

4. Disconnect fuel tank vent pipe from filler tube.
5. Support weight of fuel tank underneath cradle.

6. Remove 2 nuts and 2 bolts securing cradle to

chassis.

7. With assistance, lower LH side of fuel tank then

remove fuel tank from chassis.

8. Remove fuel tank from cradle.

9. Remove 2 scrivets securing heat shield and

remove heat shield.

10. Release securing clip and remove breather

hose from fuel tank.

Refit

1. Fit breather hose to fuel tank and secure with

clip.

2. Position heat shield and secure with scrivets.
3. With assistance, position fuel tank and cradle.
4. Fit nuts and bolts securing cradle to chassis.

Tighten bolts to 50 Nm (37 lbf.ft) and nuts to 28
Nm (21 lbf.ft).

5. Connect fuel tank vent pipe to filler tube.
6. Connect breather and filler hoses and secure

with clips.