Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Fuel Tank and Lines - Ingenium i4 2.0l Diesel / Description and Operation

Land Rover Discovery (2009–2016) Service Manual / Powertrain / Fuel System / Fuel Tank and Lines - Ingenium i4 2.0l Diesel / Description and Operation

COMPONENT LOCATION - SHEET 1 OF 2

  1. Fuel filler pipe connection
  2. Fuel pump module
  3. Fuel tank breather pipe
  4. Vent tube
  5. Support bracket
  6. Fuel level sensor - 'B'
  7. Fuel level sensor - 'A'
  8. Line - fuel supply from Fuel Fired Booster Heater (FFBH) fuel pump (if equipped)
  9. Line - fuel return
  10. Line - fuel supply
  11. Line - fuel supply from Fuel Fired Booster Heater (FFBH) fuel pump (if fitted)
  12. Fuel Fired Booster Heater (FFBH) fuel pump (if equipped)

The fuel tank is manufactured using six-layer co-extruded blow-molding technology providing both high mechanical strength and complete emissions integrity. The fuel tank is mounted under the rear seat floorpan, forward of the rear suspension.

The fuel tank has a useable capacity of:

  • 65 liters (17.17 gallons) (Vehicles fitted with EU5 engine)
  • 54 liters (14.26 gallons) (Vehicles fitted with EU6 engine)

The LP fuel pump supplies fuel to the HP fuel pump mounted on the engine.

An internal bracket allows for the attachment of the left fuel pick-up and the fuel level sensor.

An internal breather hose is connected to a stub port passing through the fuel tank casing. An external pipe and hose connect this port to the top of the filler neck. This enables the fuel tank to be filled and controls the fuel cut off during filling. Fuel level inside the tank is monitored by two fuel level sensors.

FUEL PUMP MODULE

FUEL PUMP MODULE

  1. Fuel return connection
  2. Fuel supply connection
  3. Fuel level sensor electrical connector
  4. Fuel pump electrical connector
  5. Fuel Fired Booster Heater (FFBH) supply connection
  6. Fuel inlet filter
  7. Fuel Fired Booster Heater (FFBH) suction tube and seal (if equipped)
  8. Fuel level sensor float
  9. Swirl pot
  10. Fuel level sensor - 'A'
  11. Jet pump connection - left (passive) side of fuel tank
  12. Locking ring and O-ring seal

The fuel pump module is located in the right side of the fuel tank. The fuel pump module flange is sealed to the fuel tank with an O-ring and secured with a locking ring.

The top flange of the fuel pump module assembly provides the internal and external interface for the tank electrical and fuel connections. The flange has external electrical connectors that are connected to the active and passive fuel level sensors, and the in-tank fuel pump.

The lower part of the fuel pump module forms the fuel swirl pot, and provides the location for the in-tank fuel pump and the two jet pumps. The swirl pot provides a constant reservoir of fuel for the LP fuel pump to supply the HP fuel pump.

The LP fuel pump ensures sufficient fuel is in the swirl pot to supply the engines HP fuel pump demands by supplying the fuel to power the jet pump venturis. The rapid flow of fuel through the venturi nozzle creates a depression which draws fuel back across the saddle from the left (passive) side of the fuel tank into the pump (active) side of the fuel tank. The second venturi draws fuel from the pump side of the fuel tank into the swirl pot.

Surplus fuel entering the fuel swirl pot overflows into the usable right side of the fuel tank.

For cold climate market vehicles fitted with a Fuel Fired Booster Heater (FFBH) and a FFBH fuel pump, the fuel pump module has a separate pipe connection for a fuel supply line which connects to the FFBH fuel pump. The FFBH fuel pump is mounted on the right side of the fuel tank exterior. This pipe connection is equipped with a sealed suction tube which draws fuel from the swirl pot. An additional fuel line connects the FFBH fuel pump to the FFBH fuel inlet.

FUEL LEVEL SENSORS

There are two fuel level sensors located inside the fuel tank. Fuel level sensor 'A' is attached to the swirl pot and monitors fuel level on the right side of the fuel tank. Fuel Level sensor 'B' is attached to the suction pipe carrier and monitors fuel level on the left side of the fuel tank.

Both level sensors are MAgnetic Passive Position Sensor (MAPPS) which provide a variable resistance to ground for the output from the fuel gauge.

FUEL FILLER PIPE AND BREATHER ASSEMBLY

The neck of the fuel filler pipe is positioned at the rear of the vehicle, above the rear right wheel. The filler pipe and cap is covered by a molded plastic fuel flap which is electrically locked when the vehicle is locked.

The filler cap is a conventional screw-in type which is secured to the vehicle with a lanyard. The cap has a locking mechanism which gives an audible click when the cap is correctly tightened.

The filler pipe is a stainless steel fabrication which is secured to the vehicle body with two brackets and nuts. A metal stub pipe, attached to the filler neck, provides for the attachment of the breather pipe.

A breather pipe is connected between the fuel filler neck and the fuel tank.

The breather pipe enables the fuel tank to be filled, allows for expansion of the fuel vapor and controls the fuel cut off during filling.

The fuel filler pipe attaches to a stub at the rear of the fuel tank which incorporates a check valve. The in-line check valve is mounted inside the fuel tank inlet stub, and is retained in the closed position by a spring. The check valve is only opened when the vehicle is refueled.

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