Fuel Tank: Service and Repair

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.

Fuel Pump - Defender 110:

To renew the pump, it is necessary to remove the fuel tank from the vehicle.

1. Move the vehicle to a well ventilated area and disconnect the battery. Clean the area around the pump.
2. Remove the fuel tank drain plug and allow the fuel to drain into a suitable receptacle that can be sealed afterwards. ENSURE TANK IS DRAINED COMPLETELY and refit drain plug.
3. Working from the right hand side of the vehicle, disconnect the fuel teed pipe and the spill return at the rubber connections
4. Disconnect the fuel filler hose and breather hose from the tank.
5. Note cable colors and disconnect the electrical leads from the fuel gauge unit at the left hand side of the vehicle
6. Disconnect pipes to expansion tank
7. Remove the eight nuts and bolts securing the anti-roll bar to the chassis and push the anti-roll bar down to provide access to the tank.
8. Remove the left hand lashing eye to facilitate removal of the fuel tank
9. Place a support under the fuel tank preferably one which will enable the fuel tank to be progressively lowered.
10. Remove the two nuts retaining the forward end of the tank.
11. Remove the two nuts retaining the rear end of the tank.
12. Carefully lower the tank sufficiently to enable the electrical leads to the fuel pump to be disconnected.
13. Finally remove the tank from the vehicle together with the fuel pump and rear section of the fuel feed pipe. Place tank in a safe area.

NOTE: A fuel vapor warning label must be attached to vehicle.

14. Disconnect the rear section of the fuel feed pipe from the pump.
15. Remove the five retaining screws and withdraw the fuel pump and sealing ring from the tank.
16. Cover the pump aperture in the tank to prevent the ingress of foreign matter and escape of fuel vapors.

REFIT
1. Fit the pump into the tank with a new sealing ring so that the outlet pipe is directed towards the front of the vehicle and the electrical connections to the rear.
2. Offer up tank to chassis ana connect the electrical leads; black to ground (-) and white to positive (+).

Fuel Tank Mount:

3. Locate front of tank on the two captive bolts and secure with the mounting rubber, flat and spring washers and nut.

Fuel Tank Mount:

4. Secure the rear of the tank with the two captive bolts, plain washer and Nyloc nut.
5. Connect the fuel feed and expansion tank pipes.
6. Connect the spill return pipe
7. Connect the fuel filler hose and breather pipe to the tank.
8. Fit the left hand lashing eye.
9. Fit the anti roll bar.
10. Fit the drop plate support bars if fitted.
11. Connect the fuel gage unit leads
12. Reconnect battery and check operation of pump and changeover solenoid if fitted.
13. Run engine check all connection for leaks.