Land Rover Lesson 2 Auto Trans Coolingine Rover Manual

							The fuel tank is manufactured from moulded plastic
which is a minimum of 3 mm thick. The tank is a sealed
unit with the only internal access being via the pump
module flange aperture on the top of the tank.
The flange assembly comprises a pump module flange
which contains all external pipe and electrical
connections for the tank internal components, a collar
and a clamp. The flange is fitted with a seal which
locates in the tank aperture. An arrow on the flange must
be aligned between two moulded lines on the tank,
adjacent to the pump module flange aperture, to obtain
the correct orientation of the flange. The collar is located
over the flange and is secured with the clamp. The
flange, seal, collar and clamp arrangement meets the
sealing requirements of LEV2 emissions.
The flange has a six pin external connector which
provides for electrical connections for the level sensors
and the fuel pump. This connector is wired to three push
fit connectors on the underside of the flange. A quick
release connector provides for the connection of the fuel
feed pipe and breather.
A tank carrier assembly is attached inside the tank and
is used to locate the internal tank components. The
carrier provides location for the fuel pump module, the
front level sensor, the Roll Over Valves (ROVs) and
the front jet pump.
The fuel pump module contains a number of
components. The module comprises the fuel pump, the
rear fuel level sensor, the rear jet pump, the pump inlet
filter, a second fine mesh filter and the fuel pressure
regulator, which is housed in a manifold that is mounted
in the carrier assembly. Only the pump module assembly
and level sensors are available as serviceable
components, the individual assembly components are
not available separately.
Fuel Tank and LinesLesson 2 – Powertrain
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							Fuel Tank Internal Components
Front right hand Roll Over Valve (ROV)1
Carrier assembly2
Fuel Level Vent Valve (FLVV) breather
corrugated tube
3
Front ROV corrugated tube4
Liquid Vapor Separator (LVS)5
Rear right hand ROV6
Rear left hand ROV7
Fuel pump module8
Rear fuel level sensor9
Tank breather tube10
Connector11
Fuel Level Vent Valve (FLVV)12
Front fuel level sensor13
Front left hand ROV14
Front jet pump15
The 4.4L V8 vent system is identical to the system used
on the 4.0L V6 models. The vent system comprises:
•four Roll Over Valves (ROV)
•one Fuel Level Vent Valve (FLVV)
•one Liquid Vapor Separator (LVS)
The vent system is mounted on the fuel tank internal
carrier which is assembled outside of the tank and
inserted into the tank during the blow moulding process.
None of the internal tank venting components are
serviceable.
The two rear ROVs are mounted directly onto the LVS
with rubber grommets and secured with clips.
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							The two front ROVs are located in the front of the tank
and are attached to the main beam of the carrier by a
moulded clip. Both ROVs are connected to the LVS
with a plastic corrugated tube.
The four ROVs vent directly into the LVS. Any liquid
fuel is separated from the vapor in the LVS and drains
back into the tank via the FLVV. The LVS is connected
by a corrugated tube to the fuel pump module flange.
This allows fuel vapor to exit the tank during venting.
The main purpose of the FLVV is to control the fill
volume of the tank. During filling, excess vapor is
passed via the FLVV to the LVS. The vapor then passes
from the LVS to the fuel pump module flange vent
connection via a corrugated tube. The flange vent
connection is connected to the charcoal canister which
stores the fuel vapor. During filling, when the tank
reaches its full level, the FLVV closes and prevents fuel
vapor passing through to the LVS. This causes the
pressure in the tank to rise which in turn causes the
pump filling nozzle to turn off.
Fuel Pump Module
The fuel pump module is attached to the carrier and is
located at the bottom of the swirl pot. The pump module
flange has three electrical connectors; one for the fuel
pump motor and one for each of the fuel level sensors.
All are connected to the external electrical connector
via the connectors on the underside of the fuel pump
module flange.
The pump module has a rated flow of 122 litres/hour
(32.2 US gallons/hour) at a voltage of 12.3V and an
output pressure of 4.5 bar (65.2 lbf/in2).
The fuel pump is energised by the fuel pump relay which
is located in the battery junction box. The relay is
controlled by the engine control module and energises
the relay at all times when the ignition switch is in
ignition position II.
A pump inlet filter is attached to the pump inlet port at
the bottom of the pump. The filter has a winged section
which is located vertically at the side of the pump to
ensure that a portion of the filter is off the base of the
swirl pot, to prevent premature blocking of the filter.
The filter has a 31 micron fine mesh filter with a surface
area of 70 cm2 (10.8 in2).
A second fine mesh filter is located around the top of
the fuel pump. This provides additional filtration to the
fuel before it is passed into the manifold and onto the
fuel rail. The filter has an electrical connection which
is attached to ground. The ground is required to dissipate
electrostatic charges that can build up on the fine filter.
The fuel filter outlet also incorporates a non-return valve
which prevents fuel returning to the pump when the
engine is not running. This ensures that system pressure
is maintained in the fuel feed line to the fuel rail when
the engine is not running.
Fuel Level Sensors
The sensor is a MAgnetic Passive Position Sensor
(MAPPS) which provides a variable resistance to earth
for the output from the fuel gauge. The sensor is sealed
from the fuel preventing contamination of the contacts,
increasing reliability. The front and rear fuel level
sensors are connected to the external electrical connector
on the flange via the connectors on the underside of the
fuel pump module flange.
The front sensor is attached to the front of the carrier
and is accessible via the fuel pump flange aperture. The
rear sensor is attached to the side of the swirl pot and
is also accessible via the flange aperture.
The sensor comprises a series of 51 film resistors
mounted in an arc on a ceramic surface. The resistors
are wired in series with individual contacts. A soft
magnetic foil with 51 flexible contacts is mounted a
small distance above the film resistors. A magnet,
located below the ceramic surface, is attached to the
sender unit float arm. As the float arm moves the magnet
Fuel Tank and LinesLesson 2 – Powertrain
349Technical Training (G421196) 
						

							follows the same arc as the film resistors. The magnet
pulls the flexible contacts onto the opposite film resistor
contacts forming an electrical circuit.
Sensor Operating Principle
Magnetic foil1
Spacer2
Ceramic surface3
Magnet4
Resistance film5
The film resistors are arranged in a linear arc with
resistance ranging from 51.2 to 992.11 Ohms. The
electrical output signal is output proportional to the
amount of fuel in the tank and the position of the float
arm. The measured resistance is processed by the
instrument pack to implement an anti-slosh function.
This monitors the signal and updates the fuel gauge
pointer position at regular intervals, preventing constant
pointer movement caused by fuel movement in the tank
due to cornering or braking.
A warning lamp is incorporated in the instrument cluster
and illuminates when the fuel level is at or below 10
litres (2.64 US gallons).
The fuel level sender signal is converted into a CAN
message by the instrument pack as a direct interpretation
of the fuel tank contents in litres. The ECM uses the
CAN message to store additional OBD P Codes for
misfire detection when the fuel level is below a
predetermined capacity.
Front Fuel Level Sensor Resistance/Fuel Gauge Read
out Table
Nominal Gauge
Reading
Sender Unit Resist-
ance, Ohms
NOTE: These figures are with the vehicle on level
ground. Sensor readings will differ with varying
vehicle inclinations.
Empty51
Low fuel level illumina-
tion
51
Half full294
Full798
Rear Fuel Level Sensor Resistance/Fuel Gauge Read
out Table
Nominal Gauge
Reading
Sender Unit Resist-
ance, Ohms
NOTE: These figures are with the vehicle on level
ground. Sensor readings will differ with varying
vehicle inclinations.
Empty75.5
Low fuel level illumina-
tion
120
Half full280
Full675
Fuel Pressure Regulator
The fuel pressure regulator is located in the manifold
inside the fuel tank. The regulator controls the fuel
pressure in the feed pipe to the fuel rail by allowing
some fuel to be diverted to the front jet pump.
The regulator is subject to pump output pressure and
controls the pressure of the fuel delivered to the fuel
rail to a 4.5 bar (65.2 lbf/in2). At pressures above this
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							figure, the regulator opens, decaying the pressure
supplied to the fuel rail by allowing fuel to pass to the
front jet pump. The regulator is required to maintain the
fuel pressure at the optimum pressure for correct fuel
injection.
Swirl Pot
The swirl pot is located at the rear of the fuel tank and
provides for the attachment or location of most of the
fuel pump assembly components.
The swirl pot acts as a fuel reserve, providing a constant
supply of fuel to the fuel pump irrespective of fuel
quantity or vehicle attitude. When the vehicle is level
the swirl pot contains approximately 400 cm3 (24.4 in3)
of fuel when the engine is running. The two jet pumps
ensure that fuel is constantly supplied to the swirl pot
to provide a sufficient fuel supply for the pump.
A one way valve is located in the base of the swirl pot.
The valve allows fuel from the tank to enter the swirl
pot, but prevents it from escaping.
Jet Pumps
The fuel system incorporates two jet pumps. The front
jet pump is located on the carrier near the front of the
fuel tank. The rear jet pump is located in the swirl pot
below the fuel pump. Both jet pumps operate on a
venturi effect created by the fuel at pump output pressure
passing through the jet pump. This draws additional fuel
from the tank through ports in the jet pump body,
delivering additional fuel to the swirl pot.
The front jet pump is mainly used when the vehicle is
driving downhill. The jet pump is connected via a pipe
from the fuel manifold and receives fuel diverted from
the fuel feed pipe by the pressure regulator. The front
jet pump collects fuel from the front of the tank and
transfers it into the swirl pot, ensuring a constant supply
of fuel to the pump. The jet pump has a jet nozzle of
2.1 mm diameter.
The rear jet pump operates at pump output pressure and
delivers some of the fuel at pump pressure from the rear
of the tank.
Roll Over Valves (ROVs)
Four ROVs are located on the carrier and are connected
via pipes to a liquid vapour separator. The separator,
which is also attached to the carrier, is connected via a
pipe to the tank breather outlet in the pump module
flange. The ROVs contain non-return valves which close
in the event of the vehicle overturning, preventing liquid
fuel escaping from the tank via the breather pipe.
Fuel Tank and LinesLesson 2 – Powertrain
351Technical Training (G421196) 
						

							FUEL FILLER PIPE ASSEMBLY
Fuel Filler - ROW
Filler cap1
Bracket2
Screw M63
Filler cap lanyard4
Charcoal canister breather hose5
Charcoal canister vent hose to atmosphere6
Charcoal canister (ROW)7
Rear differential breather pipe8
Tank breather pipe9
Clamp - filler hose10
Fuel filler pipe11
Screw M812
Lower mounting bracket to EPB bracket13
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							Fuel Filler - NAS
Filler cap1
DMTL pump filter2
Screw M63
Bracket4
Filler cap lanyard5
Charcoal canister breather hose6
DMTL pump vent hose to filter7
DMTL pump8
Charcoal canister (NAS)9
Rear differential breather pipe10
Tank breather pipe11
Clamp - filler hose12
Fuel filler pipe13
Screw M814
Lower mounting bracket to EPB bracket15
The fuel filler head is positioned at the rear of the
vehicle, above the right hand rear wheel. The filler head
is covered by a moulded plastic cover 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.
NOTE: The fuel filler head plastic cover does not lock
on NAS vehicles.
The filler head is a stainless steel fabrication. Two
brackets provide for the attachment of the filler head to
the vehicle body and the chassis electronic park brake
bracket.
Connections on the rear of the filler head allow for the
connection of the fuel tank breather pipe from the fuel
tank flange, the fuel filler pipe to the tank and the
charcoal canister breather pipe.
Fuel Tank and LinesLesson 2 – Powertrain
353Technical Training (G421196) 
						

							The fuel tank breather pipe has a quick release fitting
and connects to the breather pipe from the fuel tank
flange.
The fuel filler pipe locates in a short flexible hose
attached to the tank and is secured with worm drive
clamps. The canister breather pipe is routed alongside
the fuel filler pipe and attaches to the canister with a
quick release coupling.
A fourth pipe is also routed alongside the fuel filler pipe
and provides air ventilation for the charcoal canister.
On all petrol vehicles, except NAS vehicles, the pipe is
connected to the air pump port on the charcoal canister
with a quick release coupling and connects to an insect
trap at the fuel filler head. On NAS vehicles fitted with
a DMTL pump, the pipe connects to the pump vent port
and is also connected to a filter which is attached to the
filler head.
A smaller pipe, which is not associated with the fuel
system, is attached to the side of the fuel filler pipe. This
pipe connects to the rear differential and provides
breathing for the differential case. The pipe terminates
near the fuel filler head.
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							Fuel Delivery System Component Location
Filler cap and lanyard1
Rear differential breather pipe2
Fuel pump module assembly3
Fuel tank vent pipe4
Fuel Tank and LinesLesson 2 – Powertrain
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							Tank breather pipe5
Heat shield6
Cover7
Pipe - Fuel Burning Heater (FBH) pump feed (if
fitted)
8
FBH pump (if fitted)9
Pipe - Pump to filter (fuel feed)10
Pipe - Filter to pump module (fuel return)11
Pipe - Filter to engine (fuel feed)12
Pipe - Engine to fuel cooler (fuel return)13
Pipe - FBH pump to FBH (if fitted)14
Pipe - Fuel cooler to filter (fuel return)15
Pipe - HP pump to fuel cooler (fuel return)16
Fuel cooler17
Fuel filter bracket18
Fuel filter assembly19
Cradle20
Pipe - Fuel pump to filter (fuel feed)21
Pipe - Filter to pump module (fuel return)22
Fuel filler pipe23
Fuel tank24
GENERAL
The major components of the TdV6 fuel system
comprise a fuel tank, a fuel pump module, a fuel filter,
a fuel cooler, a fuel filler pipe and cap assembly and
two fuel level sensors.
The TdV6 fuel system is a high pressure common rail
system. This system uses an engine mounted and driven
high pressure pump to deliver a uniform level of
pressure to the common fuel rail which supplies all fuel
injectors.
(G421197) Technical Training356
Lesson 2 – PowertrainFuel Tank and Lines