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
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.
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.
FUEL DELIVERY SYSTEM - TD5
19-1-18 REPAIRS
Solenoid - fuel filler flap release
$% 19.55.17
Remove
1. Remove loadspace RH side trim casing.
REPAIRS, Trim casing - side - loadspace.
2. Remove 2 nuts and release solenoid from
body panel.
3. Disconnect multiplug and remove solenoid.
Refit
1. Position solenoid and connect multiplug.
2. Position solenoid to panel and tighten nuts.
3. Fit loadspace RH side trim casing.
REPAIRS, Trim casing - side - loadspace.
Switch - fuel filler flap release - up to
03MY
$% 19.55.23
Remove
1. Carefully remove switch.
2. Disconnect multiplug from switch.
3. Remove switch.
Refit
1. Connect multiplug switch.
2. Position switch and push to secure.
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