The complete new fuel pump assembly for a 1996 Land Rover Discovery 4.0L V8.
This article provides detail on replacing the fuel pump on a 1996 Land Rover Discovery 4.0L V8 - check your vehicle for applicability prior to starting any work based on this article. Documented below is a complete fuel pump assembly replacement: in a subsequent article, actual pump rebuild will be addressed, and there are aftermarket pumps available as well.
Because this work requires the gas tank to be open for a short time - which will generate significant gas fumes - you should exercise extreme caution when doing this work. Disconnect the battery, roll down all windows, work in a well-ventilated area, and eliminate any potential sources of sparks.
Diagnosing a faulty fuel pump
The diagnosis on my vehicle was very straightforward: the Disco wouldn't start, and I had a helper turn the ignition key while I listened for the pump to kick in. It didn't, so the problem was isolated after I verified with an electrical meter that the pump was indeed being powered.
Tools and Parts required for Fuel Pump Replacement
Two 14mm box wrenches
New tank-to-pump seal (optional, recommended), Genuine P/N NTC 5859
If you replace the pump with a new one which does not have flanged fuel line fittings, you will also need two coupler fittings Genuine P/N NRC9771 and two fitting bolts Genuine P/N NRC9770.
Removing the Pump
The fuel pump is located in the tank, under the rear cargo floor. Begin by removing the six phillips screws in the plastic trim at the base of the rear door. Set the trim aside, and pull up the carpet and insulating pad. The corner trim may need to be pried upward to allow access to unseat the carpet and pad from the anchors in the rearmost corners.
Carpet flipped up. Pad was previously removed due to a water leak, which led to an unpleasant surprise.
The hatch in the cargo floor which provides access to the pump.
The old pump installed in the tank.
Remove the six phillips screws which secure the hatch above the pump. Set aside, and be sure to clean the area around the pump prior to removing the pump. This will ensure no dirt or other elements fall into the tank during the course of the work.
Remove the electrical connector from the pump. Use one 14mm box wrench to hold the fitting on the fuel line, and use the other to loosen the fitting on the pump. Loosen and pull away both the return and feed lines.
The tank seal: the white arrow indicates the upper ridge, which should be secured around the lip of the tank when reinstalled.
Loosening the fuel line fittings with two 14mm box wrenches.
The old pump is ready to be removed after a thorough cleaning of the area.
Remove the plastic securing ring from the pump and tank. Carefully pull the pump straight up and out of the tank until the fuel level sensing mechanism contacts the top of the tank. Slowly tip the pump to drain as much gas from the pump assembly as possible, then work the pump out of the tank without bending the level rod. The tank seal will likely remain on the pump. Remove this seal and reinstall to tank (or use a new seal), with the uppermost ridge seated above the lip of the tank.
Installing the new Pump
This pump required new fittings due to a different design than the original pump (which had flared lines).
New pump is installed and ready.
Work the fuel level mechanism into the tank, then slowly install the pump into the tank. A smooth pace will retain a good seal at the tank and not roll the seal around the pump. Reinstall the retaining ring. Install the new fittings to the pump and reattach the fuel lines, and when complete restore the electrical connection.
After restoring the battery connections, start the vehicle and check for any leaks around the pump or fittings. Finally, button down the trim and the Rover should be all good to go!
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