2016.

0 RANGE ROVER (LG), 310-01

FUEL TANK AND LINES -

TDV6 3.0L DIESEL
S P E C I F I C AT I O N S

Capacities

LITERS

Fuel tank capacity 90 (usable)

General Specifications

ITEM SPECIFICATION

Fuel system Mechanical - recirculating

Fuel tank Multi layer plastic

High pressure fuel Located at rear of engine between the cylinder heads, belt driven
pump from the camshafts

Low pressure fuel Dual stage electric - submersible - located in fuel tank
pump

Fuel cooler Located on the left front suspension top mount assembly

Fuel filter Remotely located on the left front suspension top mount
assembly - fitted with a renewable element

Fuel tank sender Two - active and passive - passive sender unit is attached to the
units removable retaining bracket and the active sender unit is
attached to the fuel pump swirl pot

High pressure fuel 1650 bar - 23931.2 lbf/in²

pump maximum
operating pressure
 Low pressure fuel 0.5 bar - 7.25 lbf/in²
pump operating
pressure

Torque Specifications

DESCRIPTION NM LB-FT LB-IN

Fuel cooler retaining bolts 9 - 80

Fuel tank internal bracket retaining bolt 7 - 62

Fuel tank filler pipe retaining nuts 9 - 80

Fuel tank filler pipe hose clamp 3.5 - 31

Fuel tank shield retaining bolts 45 33 -

Fuel tank shield to fuel tank bolt 10 7 -

2016.0 RANGE ROVER (LG), 310-01

FUEL TANK AND LINES -

TDV6 3.0L DIESEL
D E S C R I P T I O N A N D O P E R AT I O N

C O M P O N E N T LO CAT I O N

TDV6 3.0L DIESEL - FUEL TANK AND LINES

!

ITEM DESCRIPTION

1 Fuel Filter

2 Fuel Cooler

3 Water/Fuel Mix Drain Hose

4 Water/Fuel Mix Drain Turn Wheel

5 Fuel Supply to High Pressure Diesel Injector Pump

6 Fuel Return from High Pressure Diesel Injector Pump to Fuel Cooler

7 Fuel Supply to Fuel Filter

8 Fuel Return from Fuel Filter

9 Fuel Fired Booster Heater Supply

10 Fuel Tank Refueling Breather Pipe Connection

 11 Fuel Tank Refueling Breather Pipe

12 Fuel Filler Pipe

13 Fuel Tank

14 Fuel Supply Line

15 Fuel Return Line

16 Fuel Cooler to Fuel Filter Pipe

17 High Pressure Diesel Injector Pump to Fuel Cooler Pipe

INTRODUCTION

The TDV6 3.0L diesel engine low pressure fuel system is designed to supply
fuel to the high pressure pump, it can supply a uniform level of pressure to
the common rails which supply's the fuel injectors.

F U E L TA N K

ITEM DESCRIPTION
 1 Fuel Pump Module Tank Flange

2 Fuel Tank

The fuel tank has a storage capacity of 85 liters.

Inside the fuel tank, you will find the location of the low pressure fuel pump
module assembly.

Access to the fuel tank is via the removal of the rear seat base and removal
of the low pressure pump module flange located on the right side of the
tank.

Within the fuel tank in the upper left side center section, a fuel cut-off elbow
is positioned. This is to control the fuel fill volume of the tank. During the
Refueling process, air/vapor is displaced (by the fuel entering the tank) and
exits the tank via the cut-off elbow and is conveyed by the fuel tank
Refueling breather pipe to exit the system. During filling, as the tank
reaches its full level, the fuel cut-off elbow is closed by the rising fuel and
prevents air/vapor passing through to the Refueling breather pipe. The
resulting back pressure causes Refueling to stop automatically.

The fuel cut-off elbow is always open when the fuel tank is below full,
providing an unrestricted air/vapor outlet to the Refueling breather pipe.

Fuel level inside the tank is monitored by two level sensors that are
connected top the instrument cluster.

FUEL PUMP MODULE

 !

ITEM DESCRIPTION

1 Fuel Pump Module Tank Flange

2 Fuel Cut-Off Elbow

3 Left Side Fuel Level Sensor Float

4 Suction Port Filter

5 Suction Port Pipe

6 Venturi Pump

7 Swirl Pot

8 Right Side Fuel Level Sensor Float

9 Fuel Pump Coarse Filter

10 Pressure Relief Valve

The fuel pump module is controlled by the ECM (engine control module) via
the fuel pump relay located in the RJB (rear junction box).

The electric pump collects fuel from the swirl pot at the base of the pump
and passes it from the tank to the fuel supply line to the engine mounted,
high pressure pump at a pressure of 0.5 bar.

Fuel is collected from the left side of the tank to the right side of the tank
by using a single suction tube that transfers the fuel using a venturi pump
which is powered by the fuel feed from the fuel pump.

Should the fuel pump electrical connection need to be disconnected, it is

important that the ignition is switched off. If the ignition is on in positions I
or II, the instrument cluster will store its last fuel gauge needle position prior
to power down. Once power is restored the gauge will display the last
stored position regardless of the actual level of fuel in the tank.

This could result in incorrect fuel gauge readings if the fuel tank has been
drained and not filled with exactly the same quantity of fuel that was
removed.

LOW FUEL STRATEGY

The ECM is programmed with a strategy which shuts the engine off before
the fuel tank runs dry. This is to prevent fuel system damage by air being
drawn into the high pressure fuel pump.

A misfire is induced with increasing magnitude when the fuel in the tank
reaches approximately 2.5 liters of useable fuel remaining to alert the driver
to this condition. The engine is shut down when the fuel in the tank reaches
0.00 liters of useable fuel remaining in the tank and 4.0 liters of un-useable
fuel remaining.

To reset the fuel strategy after engine shutdown, it is required that a

minimum of 4 liters of fuel is added to the fuel tank, when the vehicle is on
level ground.

FUEL LEVEL SENSORS

There are two fuel level sensors located inside the fuel tank. One sensor is
attached to the swirl pot and monitors fuel level on the right side of the
tank. The second sensor is attached to the suction pipe carrier and monitors
fuel level on the left side of the tank.

Both level sensors are MAPPS (magnetic passive position sensor) which
provide a variable resistance to ground for the output from the fuel gauge.

The electrical output signal is proportional to the amount of fuel in the tank
and the position of the float arm. The measured resistance is processed by
the instrument cluster 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.

Fuel Level Sensors - Resistance/Fuel Gauge Read Out Table

NOTE:

These figures are with the vehicle on level ground. Sensor readings
will defer with varying vehicle inclinations.

Active Side of Fuel Tank

SENDER UNIT RESISTANCE, OHMS NOMINAL GAUGE READING

992 Empty

51 Full

Passive Side of Fuel Tank

SENDER UNIT RESISTANCE, OHMS NOMINAL GAUGE READING

992 Empty

281 Full

When the fuel level becomes low, a fuel warning lamp in the instrument
cluster is illuminated and message is displayed.
The fuel level sender signal is converted into a CAN (controller area
network) message by the IC (instrument cluster) as a direct interpretation of
the fuel tank contents in liters.

F U E L F I LT E R

ITEM DESCRIPTION

1 Fuel Cooler to Fuel Filter Pipe

2 Fuel Supply to Fuel Filter Pipe

3 High Pressure Diesel Injector Pump to Fuel Cooler Pipe

4 Fuel Filter to High Pressure Diesel Injector Pump Pipe

5 Water/Fuel Mix Drain Hose

6 Water in Fuel Sensor

The fuel filter is disposable canister that has four quick release connections.

The fuel filter is fitted with a removable water sensor which is secured at the
base of the filter. The sensor can be unscrewed and fitted to a new filter.
The water in fuel sensor housing also incorporates a water drain plastic turn
wheel that allows the water/fuel mix to be drained from the filter via the
drain hose to the underside of the vehicle.

Water in the fuel filter is sensed by the ECM, the ECM transmits a message
on the HS (high speed) CAN powertrain bus to the IC (instrument cluster)
which displays a message 'WATER IN FUEL' in the message center.

FUEL COOLER

ITEM DESCRIPTION

1 Coolant Inlet Connection

2 Fuel Inlet Connection

3 Coolant Outlet Connection

4 Fuel Outlet Connection

The fuel cooler is designed to cool fuel returning from the high pressure
pump before it is sent back to the fuel tank via the return line. Fuel is cooled
by heat transfer through the internal galleries within the coolant assisted
fuel cooler.

The fuel cooler is connected to the cooling system. The fuel cooler receives
cooled coolant from a dedicated cooler located in front of the engine
coolant radiator. This allows for engine coolant to be cooled before it
passes through the fuel cooler improving the efficiency of the fuel cooler.

For additional Information, refer to: Engine Cooling (303-03A, Description

and Operation)

FUEL FILLER PIPE

ITEM DESCRIPTION

1 Fuel Cap

2 Fuel Refueling Breather Pipe

3 Fuel Filler Pipe

The fuel filler pipe locates into the tank and incorporates a spit back flap in
the tank end of the pipe. The flap is spring loaded cover which acts as a one
way valve, allowing the tank to be filled but preventing fuel leaving the tank
into the filler pipe.

A connection at the top right side of the filler head allows for the
connection of the fuel tank Refueling breather pipe.

The filler pipe incorporates a fuel guard system to prevent accidental filling
of the tank with petrol.

FUEL GUARD

Passive Fuel Guard System

ITEM DESCRIPTION

1 Filler neck

2 Flap

3 Reset slots

4 Spigots

5 Reset tool
 6 Spring

The passive fuel guard system comprises a mechanically operated flap which
is triggered when the smaller diameter filler nozzle tube, used on petrol
(gasoline) pumps, is inserted in the filler neck. The shut off flap is actuated
and blocks the sensor port on the fuel pump nozzle, causing it to
automatically switch off. The shut off flap is locked in this position by a latch
mechanism, once it has been activated.

A reset tool is provided and stored within the vehicle. The tool is used to
reset the fuel guard device if triggered. The tool is inserted into the filler
opening as far as possible with the spigots pointing upper most. Once the
two spigots on the tool are located in the slots it can be pulled outwards,
releasing a latch and allowing the shut off flap to be opened by its own
spring pressure.

The shut off flap is colored yellow so that it is clearly visible within the
entrance of the fuel filler pipe when activated, the shut off flap has a
'Handbook' symbol on it.

A 25mm diameter diesel fuel pump nozzle will not activate the fuel guard
because the nozzle stops against two molded lugs. However, if a 21mm
diameter unleaded gasoline pump nozzle is inserted into the housing, its
smaller diameter allows it to pass the two molded lugs. The nozzle strikes
two pins on the inside of the filler housing which move forward. This
movement rotates the shut-off flap which is then held in place when the
nozzle is removed by the latch mechanism.

NOTE:

Russian markets do not use the fuel guard system and are fitted with
a conventional filler neck.

Active Fuel Guard System

Normal State

ITEM DESCRIPTION

1 Sensing tabs in normal state

2 Fuel guard flap closed

Open State

ITEM DESCRIPTION

1 Sensing tabs in open state

2 Fuel guard flap open

The fuel guard consists of a mechanically-operated flap and three fuel
nozzle sensing tabs. When a 25mm diameter diesel fuel filler nozzle tube is
inserted into the fuel filler pipe, the three sensing tabs depress releasing the
flap into the open position. If a smaller 21mm diameter filler nozzle tube,
used on petrol (gasoline) pumps, is inserted in the fuel filler pipe, the three
sensing tabs will not depress and the flap will not release, so this blocks the
fuel nozzle from entering the filler pipe.

Adaptor Funnel

If the vehicle travels to a market where differentiation of fuel nozzle size or if

the vehicle runs out of fuel and must be refilled at the road side using a
reserve can, then an adaptor funnel is provided to allow the misfuelling
device to be temporarily overridden.

The adaptor funnel will be located either in the glove compartment or in the
luggage compartment alongside the tool kit.

CONTROL DIAGRAM
!

ITEM DESCRIPTION

1 Battery

2 Battery Junction Box 2 (BJB2)

3 Battery Junction Box (BJB)

4 Auxiliary Junction Box (AJB)

5 Engine Junction Box (EJB)

6 Engine Control Module (ECM)

7 Central Junction Box (CJB)

8 Instrument Cluster (IC)

9 Fuel Level Sensor (2 Of)

10 Low Pressure Fuel Pump

11 Rear Junction Box (RJB)
2016.0 RANGE ROVER (LG), 310-01

FUEL TANK AND LINES -

TDV6 3.0L DIESEL
DIAGNOSIS AND TESTING

P R I N C I P L E O F O P E R AT I O N

For a detailed description of the fuel tank and lines system and operation,
refer to the relevant Description and Operation section of the workshop
manual.
REFER to: Fuel Tank and Lines (310-01A Fuel Tank and Lines - TDV6 3.0L
Diesel, Description and Operation).

I N S P E C T I O N A N D V E R I F I CAT I O N
 WARNINGS:

Do NOT carry out any work on the fuel system with the engine
running. The fuel pressure within the system can be as high as 2000
bar (29,008 lb/in²). Failure to follow this instruction may result in
personal injury.

Eye protection must be worn at all times when working on or near

any fuel related components. Failure to follow this instruction may
result in personal injury.

This procedure involves fuel handling. Be prepared for fuel spillage

at all times and always observe fuel handling precautions. Failure to
follow this instruction may result in personal injury.

After carrying out repairs, the fuel system must be checked visually
for leaks. This should be done after the engine has been run, but
with the engine switched OFF. Failure to follow this instruction may
result in personal injury.

If taken internally, DO NOT induce vomiting. Seek immediate

medical attention. Failure to follow this instruction may result in
personal injury.

If fuel contacts the eyes, flush the eyes with cold water or eyewash
solution and seek medical attention. Failure to follow this
instruction may result in personal injury.

Wash hands thoroughly after handling, as prolonged contact may

cause irritation. Should irritation develop, seek medical attention.
Failure to follow this instruction may result in personal injury.

CAUTIONS:

Before disconnecting any part of the system, it is imperative that all

dust, dirt and debris is removed from around components to
prevent ingress of foreign matter into the fuel system. Failure to
follow this instruction may result in damage to the vehicle.

The fuel pipes between the injectors and the rail must be discarded
after each use, and new pipes installed. Failure to follow this
instruction may result in damage to the vehicle.

It is essential that absolute cleanliness is observed when working

with these components. Always install blanking plugs to any open
orifices or lines. Failure to follow this instruction may result in
damage to the vehicle.

Make sure that the workshop area in which the vehicle is being
worked on is as clean and dust-free as possible. Areas in which
work on clutches, brakes or where welding or machining are carried
out are not suitable in view of the risk of contamination to the fuel
system. Failure to follow this instruction may result in damage to
the vehicle.

Make sure that any protective clothing worn is clean and made
from lint-free non-flocking material. Failure to follow this instruction
may result in damage to the vehicle.

Make sure that any protective gloves worn are new and are of the
non-powdered latex type. Failure to follow this instruction may
result in damage to the vehicle.

Make sure that clean, non-plated tools are used. Clean tools using a
new brush that will not lose it's bristles and fresh cleaning fluid prior
to starting work on the vehicle. Failure to follow this instruction may
result in damage to the vehicle.

Use a steel-topped work bench and cover it with clean, lint-free,

non-flocking material. Failure to follow this instruction may result in
damage to the vehicle.

Diagnosis by substitution from a donor vehicle is NOT acceptable.

Substitution of control modules does not guarantee confirmation of
a fault and may also cause additional faults in the vehicle being
checked and/or the donor vehicle.
 NOTES:

Check and rectify basic faults before beginning diagnostic routines

involving pinpoint tests.

When measuring fuel sender resistance values with a multimeter, it

is critical to use the correct multimeter setting. The multimeter
should NOT be on the 'Auto' setting and MUST be set to 'Manual'.
This will help prevent incorrect diagnosis and unnecessary
replacement of fuel senders. If the multimeter range is set at 'Auto'
then, during a sweep of the sender from 50 Ohms to 998 Ohms,
the multimeter has to change its measurement range. For
approximately 1 second, during the range switch over point, the
multimeter display indicates an open circuit. This can lead to a mis-
diagnosis of a fuel sender fault.

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection

MECHANICAL ELECTRICAL

Fuel level Battery charge and condition

Contaminated fuel Fuse(s)

Fuel supply line(s) Fuel pump module relay

Fuel return line(s) Fuel pump module

High-pressure fuel supply line(s) Electrical connector(s)

Fuel tank filler pipe Damaged or corroded wiring harness

Fuel leak(s) Fuel volume control valve

Fuel tank Fuel pressure control valve

Fuel filler cap Engine control module

Fuel filter

Push connect fittings

Fuel rail
 Fuel injection pump

Exhaust gas recirculation system

3. If an obvious cause for an observed or reported concern is found,

correct the cause (if possible) before proceeding to the next step.

4. If the cause is not visually evident, verify the symptom and refer to the
Symptom Chart, alternatively check for Diagnostic Trouble Codes
(DTCs) and refer to the DTC Index.

SYMPTOM CHART

SYMPTOM POSSIBLE CAUSES ACTION

Engine Low/contaminated Check the fuel level and condition. Check the
cranks, but fuel low pressure fuel pump operation. Using the
does not manufacturer approved diagnostic system,
Air leakage
start perform routine - Inline diagnostic unit 2 non-
Low-pressure fuel intrusive test - Low pressure fuel pump. Draw
system fault off approximately 1 ltr (2.11 pints) of fuel and
allow to stand for 1 minute. Check to make
Fuel pump module sure there is no separation of the fuel
(lift pump) fault indicating water or other liquid in the fuel.
Blocked fuel filter Check the intake air system for leaks. Check
the lift pump operation, check the low-
Fuel volume regulator pressure fuel system for leaks/damage. Check
blocked/contaminated the fuel filter, check for DTCs indicating a fuel
Fuel pressure control volume or pressure control valve fault. Check
valve the fuel pump. Check the crankshaft position
blocked/contaminated sensor circuits. Refer to the electrical guides

Fuel pump fault

Crankshaft position
sensor

Difficult to Glow plug system Check the glow plug circuits. Refer to the
start fault (very cold electrical guides. Check the fuel
conditions) level/condition. Check the low pressure fuel
pump operation. Using the manufacturer
Low/contaminated
approved diagnostic system, perform routine -
fuel
Inline diagnostic unit 2 non-intrusive test - Low
Air leakage pressure fuel pump. Draw off approximately 1
ltr (2.11 pints) of fuel and allow to stand for 1
Fuel pump module minute. Check to make sure there is no
 (lift pump) fault separation of the fuel indicating water or other
liquid in the fuel. Check the intake air system
Low-pressure fuel
for leaks. Check the lift pump operation, check
system fault
the low-pressure fuel system for
Blocked fuel filter leaks/damage. Check the fuel filter, check for
DTCs indicating a fuel volume or pressure
Fuel volume control control valve fault. Check the exhaust gas
valve recirculation system
blocked/contaminated

Fuel pressure control

valve
blocked/contaminated

Exhaust gas
recirculation valve(s)
fault

Rough idle Intake air system fault Check the intake air system for leaks. Check
the low pressure fuel pump operation. Using
Low/contaminated
the manufacturer approved diagnostic system,
fuel
perform routine - Inline diagnostic unit 2 non-
Low-pressure fuel intrusive test - Low pressure fuel pump. Check
system fault the fuel level/condition. Draw off
approximately 1 ltr (2.11 pints) of fuel and
Blocked fuel filter allow to stand for 1 minute. Check to make
Fuel volume control sure there is no separation of the fuel
valve indicating water or other liquid in the fuel.
blocked/contaminated Check the low-pressure fuel system for
leaks/damage. Check the fuel filter, check for
Fuel pressure control DTCs indicating a fuel volume or pressure
valve control valve fault. Check the exhaust gas
blocked/contaminated recirculation system
Exhaust gas
recirculation valve(s)
fault

Lack of Intake air system fault Check the intake air system for leakage or
power when restriction. Check for a blockage/restriction in
Restricted exhaust
accelerating the exhaust system, install new components as
system
necessary. Check the low pressure fuel pump
Low fuel pressure operation. Using the manufacturer approved
diagnostic system, perform routine - Inline
Exhaust gas diagnostic unit 2 non-intrusive test - Low
recirculation valve(s) pressure fuel pump. Check for DTCs indicating
fault a fuel pressure fault. Check the exhaust gas
Turbocharger actuator recirculation system. Check turbocharger
fault actuator

Engine Air leakage Check the intake air system for leaks. Check
stops/stalls the fuel level/condition. Using the
Low/contaminated
 fuel manufacturer approved diagnostic system,
perform routine - Inline diagnostic unit 2 non-
Low-pressure fuel
intrusive test - Low pressure fuel pump. Draw
system fault
off approximately 1 ltr (2.11 pints) of fuel and
High pressure fuel allow to stand for 1 minute. Check to make
leak sure there is no separation of the fuel
indicating water or other liquid in the fuel.
Fuel volume control Check the fuel system for leaks/damage:
valve Check for DTCs indicating a fuel volume or
blocked/contaminated pressure control valve fault. Check the exhaust
Fuel pressure control gas recirculation system
valve
blocked/contaminated

Exhaust gas
recirculation valve(s)
fault

Engine Low/contaminated Check the fuel level/condition. Check the low

judders fuel pressure fuel pump operation. Using the
manufacturer approved diagnostic system,
Air ingress
perform routine - Inline diagnostic unit 2 non-
Low-pressure fuel intrusive test - Low pressure fuel pump. Draw
system fault off approximately 1 ltr (2.11 pints) of fuel and
allow to stand for 1 minute. Check to make
Fuel metering valve sure there is no separation of the fuel
blocked/contaminated indicating water or other liquid in the fuel.
Fuel volume control Check the intake air system for leaks. Check
valve the low-pressure fuel system for
blocked/contaminated leaks/damage. Check the high pressure fuel
system for leaks, check for DTCs indicating a
Fuel pressure control fuel volume or pressure control valve fault.
valve Check the fuel pump
blocked/contaminated

High pressure fuel

leak

Fuel pump fault

Excessive Low-pressure fuel Check the low-pressure fuel system for

fuel system fault leaks/damage. Check the low pressure fuel
consumption pump operation. Using the manufacturer
Fuel volume control
approved diagnostic system, perform routine -
valve
Inline diagnostic unit 2 non-intrusive test - Low
blocked/contaminated
pressure fuel pump. Check for DTCs indicating
Fuel pressure control a fuel volume or pressure control valve fault.
valve Check the fuel temperature sensor, fuel pump,
blocked/contaminated etc for leaks. Check for injector DTCs. Check
the exhaust gas recirculation system
Fuel temperature
sensor leak

High pressure fuel

 leak

Injector(s) fault

Exhaust gas
recirculation valve(s)
fault

M I S - F U E L L I N G I S S U E S / A C C I D E N TA L LY
F I L L I N G T H E F U E L TA N K W I T H G AS O L I N E
INSTEAD OF DIESEL
 NOTES:

The customer MUST be informed prior to vehicle hand-over of the

consequences of adding gasoline to the fuel tank instead of diesel.

The cost of this repair work is not Jaguar Land Rover's

responsibility. If the customer does not have all of the appropriate
work carried out, warranty may be refused on all affected
components.

If the customer refuses the advised repair or wants a lower level

repair than advised, the vehicle must be added to the Restricted
Warranty Register.

Vehicle mis-fuelling will not result in a formal warranty restriction if

the approved repair has been completed.

The symptom charts below describe the four possible scenarios of a

customer incorrectly fuelling a diesel engine vehicle with gasoline.
When customers report a mis-fuel, allow them to fully explain
exactly what took place before advising the necessary repair.

The procedures listed below are for guidance only. The relevant
sections of TOPIx must be referred to for all detailed procedures
and replacement of parts.

Purge operation of the low pressure fuel pumps on the following

vehicle lines is activated when the drivers door is opened: Jaguar
XE, Jaguar XF, Jaguar F-Pace. For all other vehicle lines, the purge
operation of the low pressure fuel pumps is activated when the
ignition is switched on.

Mis-fuelling Procedure 1

SYMPTOM POSSIBLE CAUSES ACTION

Mis-fuelling issue. The vehicle has been 1. Referring to the relevant section
The diesel fuel incorrectly fuelled and the in the workshop manual, drain the
tank has been ignition switch has NOT fuel tank
filled with gasoline been switched to ON
 2. Remove the fuel tank assembly

3. Remove the primary fuel

pump/sender module and in-tank
transfer pipe. Invert the
pump/sender module to drain
excess fuel

4. Remove all traces of residual fuel

within the fuel tank using clean
absorbent cloth/paper

5. Flush the pump/sender module

and in tank transfer pipe with clean
diesel

6. Reassemble the pump/sender

module and in tank transfer pipe to
the fuel tank and install to the
vehicle

7. Fully fill the fuel tank with clean

diesel

8. Road test the vehicle for at least

10 miles/16Km

9. Return the vehicle to the

customer

Mis-fuelling Procedure 2

SYMPTOM POSSIBLE CAUSES ACTION

Mis-fuelling issue. The vehicle has been 1. Referring to the relevant

The diesel fuel tank incorrectly fuelled and the section in the workshop manual,
has been filled with ignition switch has been drain the fuel tank
gasoline switched to the ON position
2. Remove the fuel pump
module and fuel level sensor

3. Remove all traces of residual

fuel within the fuel tank using
clean absorbent cloth/paper

4. Invert the fuel pump module

and fuel level sensor to remove
all traces of residual fuel

5. Remove the fuel filter and

discard

6. Disconnect the fuel feed to

the high-pressure fuel pump

7. Flush all the fuel lines with

 clean diesel

8. Reassemble the fuel pump

module and fuel level sensor to
the fuel tank

9. Install a new fuel filter

10. Fully fill the fuel tank with

clean diesel

11. Road test the vehicle for at

least 10 miles/16Km, checking
for normal engine operation
and no stored DTC'S

12. Return the vehicle to the

customer

Mis-fuelling Procedure 3

SYMPTOM POSSIBLE ACTION

CAUSES

Mis-fuelling issue. The The vehicle has 1. Referring to the relevant section in
diesel fuel tank has been run for less than the workshop manual, drain the fuel
filled with gasoline two minutes tank

2. The residual fuel from all removed

parts needs to be checked for metal
particles using a magnet

3. Remove the fuel pump module and

fuel level sensor

4. Remove all traces of residual fuel

within the fuel tank using clean
absorbent cloth/paper

5. Invert the fuel pump module and fuel

level sensor to remove all traces of
residual fuel

6. Remove the fuel filter and discard

7. Disconnect the fuel feed to the high-

pressure fuel pump

8. Flush all the fuel lines with clean

diesel

9. If no metal particles are detected, go

to step 11

10. If metal particles are present, go to

procedure 4 and carry out step 3 to
step 8
 11. Reassemble the fuel pump module
and fuel level sensor to the fuel tank

12. Install a new fuel filter

13. Fully fill the fuel tank with clean

diesel

14. Road test the vehicle for at least 10

miles/16Km, checking for normal
engine operation and no DTC'S

15. Return the vehicle to the customer

Mis-fuelling Procedure 4

SYMPTOM POSSIBLE CAUSES ACTION

Mis-fuelling The vehicle has been 1. Referring to the relevant section in

issue. The diesel driven until it stops or over the workshop manual, drain the fuel
fuel tank has two minutes. The entire tank
been filled with fuel system will need
2. Clean and flush all the low pressure
gasoline reworking
fuel pipes

3. Replace the fuel filter

4. Replace the high pressure fuel

pump

5. Replace all the high pressure fuel

pipes

6. Replace the diverter pipe and both

fuel rails

7. Replace the fuel cooler

8. Replace all the fuel injectors

9. Remove the fuel pump module and

fuel level sensor

10. Remove all the traces of residual

fuel within the fuel tank using clean
absorbent cloth/paper

11. Invert the fuel pump module and

fuel level sensor to remove all the
traces of residual fuel

12. Reassemble the fuel pump

module and fuel level sensor to the
fuel tank

13. Fully fill the fuel tank with clean

diesel
 14. Road test the vehicle for at least
10 miles/16Km, checking for normal
engine operation and that no stored
diagnostic trouble codes are logged

15. Return the vehicle to the

customer

DTC INDEX

For a list of Diagnostic Trouble Codes (DTCs) that could be logged on this
vehicle, please refer to Section 100-00.
REFER to: Diagnostic Trouble Code Index - TDV6 3.0L Diesel - Gen 1.5,
DTC: Engine Control Module (ECM) (100-00 General Information,
Description and Operation).
2016.0 RANGE ROVER (LG), 310-01

FUEL TANK AND LINES - TDV6 3.0L DIESEL

FUEL COOLER (G1509635)

R E M O V A L A N D I N S TA L L AT I O N

REMOVAL

WARNINGS:

The spilling of fuel is unavoidable during this operation. Ensure that

all necessary precautions are taken to prevent fire and explosion.

Do not carry or operate cellular phones when working on or near

any fuel related components. Highly flammable vapors are always
present and may ignite. Failure to follow these instructions may
result in personal injury.

Do not smoke or carry lighted tobacco or open flame of any type

when working on or near any fuel related components. Highly
flammable mixtures are always present and may ignite. Failure to
follow these instructions may result in personal injury.

If fuel contacts the eyes, flush the eyes with cold water or eyewash
solution and seek medical attention.
 CAUTION:

Diesel fuel injection equipment is manufactured to very precise

tolerances and fine clearances. It is therefore essential that absolute
cleanliness is observed when working with these components. Always
install blanking plugs to any open orifices or lines. Failure to follow
this instruction may result in foreign matter ingress to the fuel
injection system.

NOTES:

Removal steps in this procedure may contain installation details.

Some variation in the illustrations may occur, but the essential

information is always correct.

1. Disconnect the battery ground cable.

Refer to: Specifications (414-00 Battery and Charging System -
General Information, Specifications).

2. Refer to: Left Air Cleaner (303-12A Intake Air Distribution and
Filtering - TDV6 3.0L Diesel - Gen 2/TDV6 3.0L Diesel, Removal and
Installation).
3.
!

Torque: 10 Nm

4.
!

Torque: 10 Nm

5.
CAUTION:

Be prepared to collect escaping coolant.

 NOTE:

Make sure that all openings are sealed. Use new blanking
caps.

6.
CAUTIONS:

Make sure that all openings are sealed. Use new blanking
caps.

Be prepared to collect escaping fuel.

 !

7.
!

Torque: 10 Nm

I N STA L L AT I O N

1. To install, reverse the removal procedure.

2016.0 RANGE ROVER (LG), 310-01

FUEL TANK AND LINES - TDV6 3.0L DIESEL

FUEL FILTER ELEMENT (G1509639)

R E M O V A L A N D I N S TA L L AT I O N

REMOVAL
 WARNINGS:

Diesel fuel injection equipment is manufactured to very precise

tolerances and fine clearances. It is therefore essential that absolute
cleanliness is observed when working with these components.
Always install new blanking plugs to any open orifices or lines.
Failure to follow this instruction may result in foreign matter ingress
to the fuel injection system.

The spilling of fuel is unavoidable during this operation. Make sure

that all necessary precautions are taken to prevent fire and
explosion.

Do not carry or operate cellular phones when working on or near

any fuel related components. Highly flammable vapors are always
present and may ignite. Failure to follow these instructions may
result in personal injury.

Do not smoke or carry lighted tobacco or open flame of any type

when working on or near any fuel related components. Highly
flammable vapors are always present and may ignite. Failure to
follow these instructions may result in personal injury.

If fuel contacts the eyes, flush the eyes with cold water or eyewash
solution and seek immediate medical attention.

Wash hands thoroughly after fuel handling, as prolonged contact

may cause irritation. Should irritation develop, seek medical
attention.

NOTE:

Removal steps in this procedure may contain installation details.

1. Refer to: Diesel Fuel System Health and Safety Precautions (100-00
General Information, Description and Operation).
2. Disconnect the battery ground cable.
Refer to: Specifications (414-00 Battery and Charging System -
General Information, Specifications).

3.
!

4.
!
5.
CAUTIONS:

Before disconnecting or removing components, ensure the

area around the joint faces and connections are clean. Plug
open connections to prevent contamination.

Be prepared to collect escaping fuel.

6.
!
7.
CAUTION:

Note the fitted position of the component prior to removal.

I N STA L L AT I O N

1.
CAUTION:

Make sure that the fuel filter is correctly aligned. Failure to

follow this instruction may result in damage to the vehicle.

To install, reverse the removal procedure.

2. Refer to: Low-Pressure Fuel System Bleeding (310-00 Fuel System -

General Information, General Procedures).
2016.0 RANGE ROVER (LG), 310-01

FUEL TANK AND LINES - TDV6 3.0L DIESEL

FUEL LEVEL SENSOR (G1520340)

R E M O V A L A N D I N S TA L L AT I O N

REMOVAL
 WARNINGS:

After carrying out repairs, the fuel system must be checked visually
for leaks. Failure to follow this instruction may result in personal
injury.

This procedure involves fuel handling. Be prepared for fuel spillage

at all times and always observe fuel handling precautions. Failure to
follow these instructions may result in personal injury.

The spilling of fuel is unavoidable during this operation. Ensure that

all necessary precautions are taken to prevent fire and explosion.

Do not carry or operate cellular phones when working on or near

any fuel related components. Highly flammable vapors are always
present and may ignite. Failure to follow these instructions may
result in personal injury.

Do not smoke or carry lighted tobacco or open flame of any type

when working on or near any fuel related components. Highly
flammable vapors are always present and may ignite. Failure to
follow these instructions may result in personal injury.

If fuel contacts the eyes, flush the eyes with cold water or eyewash
solution and seek immediate medical attention.

Wash hands thoroughly after fuel handling, as prolonged contact

may cause irritation. Should irritation develop, seek medical
attention.

CAUTION:

Make sure the workshop area in which the vehicle is being worked on
is as clean and as dust free as possible. Foreign matter from work on
clutches, brakes or from machining or welding operations can
contaminate the fuel system and may result in later malfunction.
 NOTE:

Removal steps in this procedure may contain installation details.

1.
WARNING:

Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Refer to: Diesel Fuel System Health and Safety Precautions (100-00
General Information, Description and Operation).

3. Disconnect the battery ground cable.

Refer to: Specifications (414-00 Battery and Charging System -
General Information, Specifications).

4. Refer to: Fuel Pump and Sender Unit (310-01E Fuel Tank and Lines -
SDV6 3.0L Diesel - Hybrid Electric Vehicle, Removal and
Installation).

5.
!
 Torque: 7 Nm

I N STA L L AT I O N

1. To install, reverse the removal procedure.

2016.0 RANGE ROVER (LG), 310-01

FUEL TANK AND LINES - TDV6 3.0L DIESEL

FUEL PUMP AND SENDER

UNIT (G1509636)

R E M O V A L A N D I N S TA L L AT I O N

REMOVAL
 WARNINGS:

After carrying out repairs, the fuel system must be checked visually
for leaks. Failure to follow this instruction may result in personal
injury.

This procedure involves fuel handling. Be prepared for fuel spillage

at all times and always observe fuel handling precautions. Failure to
follow these instructions may result in personal injury.

The spilling of fuel is unavoidable during this operation. Ensure that

all necessary precautions are taken to prevent fire and explosion.

Do not carry or operate cellular phones when working on or near

any fuel related components. Highly flammable vapors are always
present and may ignite. Failure to follow these instructions may
result in personal injury.

Do not smoke or carry lighted tobacco or open flame of any type

when working on or near any fuel related components. Highly
flammable vapors are always present and may ignite. Failure to
follow these instructions may result in personal injury.

If fuel contacts the eyes, flush the eyes with cold water or eyewash
solution and seek immediate medical attention.

Wash hands thoroughly after fuel handling, as prolonged contact

may cause irritation. Should irritation develop, seek medical
attention.

CAUTION:

Make sure the workshop area in which the vehicle is being worked on
is as clean and as dust free as possible. Foreign matter from work on
clutches, brakes or from machining or welding operations can
contaminate the fuel system and may result in later malfunction.
 NOTE:

Removal steps in this procedure may contain installation details.

1.
WARNING:

Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Refer to: Diesel Fuel System Health and Safety Precautions (100-00
General Information, Description and Operation).

3. Disconnect the battery ground cable.

Refer to: Specifications (414-00 Battery and Charging System -
General Information, Specifications).

4. Refer to: Fuel Tank Draining (310-00 Fuel System - General

Information, General Procedures).

5.
!
 I N STA L L AT I O N

1. To install, reverse the removal procedure.

2016.0 RANGE ROVER (LG), 310-01

FUEL TANK AND LINES - TDV6 3.0L DIESEL

FUEL TANK ( G 1 6 7 6 1 74 )

R E M O V A L A N D I N S TA L L AT I O N

REMOVAL
 WARNINGS:

After carrying out repairs, the fuel system must be checked visually
for leaks. Failure to follow this instruction may result in personal
injury.

This procedure involves fuel handling. Be prepared for fuel spillage

at all times and always observe fuel handling precautions. Failure to
follow these instructions may result in personal injury.

The spilling of fuel is unavoidable during this operation. Ensure that

all necessary precautions are taken to prevent fire and explosion.

Do not carry or operate cellular phones when working on or near

any fuel related components. Highly flammable vapors are always
present and may ignite. Failure to follow these instructions may
result in personal injury.

Do not smoke or carry lighted tobacco or open flame of any type

when working on or near any fuel related components. Highly
flammable vapors are always present and may ignite. Failure to
follow these instructions may result in personal injury.

If fuel contacts the eyes, flush the eyes with cold water or eyewash
solution and seek immediate medical attention.

Wash hands thoroughly after fuel handling, as prolonged contact

may cause irritation. Should irritation develop, seek medical
attention.

CAUTION:

Make sure the workshop area in which the vehicle is being worked on
is as clean and as dust free as possible. Foreign matter from work on
clutches, brakes or from machining or welding operations can
contaminate the fuel system and may result in later malfunction.
 NOTE:

Removal steps in this procedure may contain installation details.

! All vehicles

1.
WARNING:

Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Refer to: Diesel Fuel System Health and Safety Precautions (100-00,
Description and Operation).

3. Disconnect the battery ground cable.

Refer to: Specifications (414-00 Battery and Charging System -
General Information, Specifications).

4. Refer to: Fuel Tank Draining (310-00 Fuel System - General

Information, General Procedures).

5.
NOTE:

Repeat the procedure for the other side.

Refer to: Rear Door Lower Moulding - Short Wheelbase (501-08

Exterior Trim and Ornamentation, Removal and Installation).
Refer to: Rear Rocker Panel Moulding - Long Wheel Base (501-08
Exterior Trim and Ornamentation, Removal and Installation).

6. Refer to: Rear Driveshaft - TDV6 3.0L Diesel (205-01 Driveshaft,

 Removal and Installation).
Refer to: Rear Driveshaft - SDV6 3.0L Diesel - Hybrid Electric Vehicle
(205-01 Driveshaft, Removal and Installation).
Refer to: Rear Driveshaft - TDV8 4.4L Diesel (205-01 Driveshaft,
Removal and Installation).

! Short wheelbase

7.
CAUTION:

LH illustration shown, RH is similar.

NOTE:

Repeat the procedure for the other side.

"

! Long wheelbase
8.
CAUTION:

RH illustration shown, LH is similar.

NOTE:

Repeat the procedure for the other side.

"

! All vehicles

9.
CAUTION:

Be prepared to collect escaping fuel.

 "

10.
NOTE:

Some variation in the illustrations may occur, but the essential

information is always correct.

"

Torque: 45 Nm
11.
NOTE:

Do not disassemble further if the component is removed for

access only.

"

12.
"

Torque: 10 Nm
13.
"

14.
"

Torque: 7 Nm

I N STA L L AT I O N

1. To install, reverse the removal procedure.

2016.0 RANGE ROVER (LG), 310-01

FUEL TANK AND LINES - TDV6 3.0L DIESEL

FUEL TANK FILLER PIPE (G1509645)

R E M O V A L A N D I N S TA L L AT I O N

REMOVAL

WARNINGS:

The spilling of fuel is unavoidable during this operation. Ensure that

all necessary precautions are taken to prevent fire and explosion.

Do not carry or operate cellular phones when working on or near

any fuel related components. Highly flammable vapors are always
present and may ignite. Failure to follow these instructions may
result in personal injury.

Do not smoke or carry lighted tobacco or open flame of any type

when working on or near any fuel related components. Highly
flammable vapors are always present and may ignite. Failure to
follow these instructions may result in personal injury.

If fuel contacts the eyes, flush the eyes with cold water or eyewash
solution and seek immediate medical attention.

Wash hands thoroughly after fuel handling, as prolonged contact

may cause irritation. Should irritation develop, seek medical
attention.
 NOTE:

Removal steps in this procedure may contain installation details.

! All vehicles

1.
WARNING:

Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Refer to: Petrol and Petrol-Ethanol Fuel Systems Health and Safety
Precautions (100-00 General Information, Description and
Operation).
Refer to: Diesel Fuel System Health and Safety Precautions (100-00
General Information, Description and Operation).

! Vehicles with petrol engine

3. Refer to: Fuel System Pressure Release - GTDi 2.0L Petrol/V6 S/C
3.0L Petrol /V8 N/A 5.0L Petrol/V8 S/C 5.0L Petrol (310-00 Fuel
System - General Information, General Procedures).

! All vehicles

4. Refer to: Rear Subframe (502-00 Uni-Body, Subframe and Mounting

System, Removal and Installation).
5.
NOTE:

Some variation in the illustrations may occur, but the essential

information is always correct.

"

6.
"
7.
"

8.
"
9.
"

10.
"

Torque: 10 Nm

11.
CAUTION:

Be prepared to collect escaping fuel.

 "

Torque:
M6 10 Nm
Clamp 3.5 Nm

I N STA L L AT I O N

1. To install, reverse the removal procedure.