Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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After examining the fuel pumps returned under claim for the above vehicles, it has been found that a high percentage of returns have no operating fault found with them. The normal complaint is “not pumping”, or “fuel starvation”. In some cases the fault may be cured when a new fuel pump is fitted, but returns shortly afterwards. There are two common causes of these symptoms on the vehicle, besides the fuel pump: 1) The Rubber Fuel Supply Pipe This may be perished or weakened, resulting in a partial or total collapse of the internal bore, restricting the fuel flow. The perishing of the pipe can also lead to air leaks on the suction feed to the fuel pump, so that the pump sucks air as well as fuel, reducing the lift efficiency of the fuel pump. 2) The In-Line Fuel Filter The filter should be changed at intervals of 20,000miles (32,000Km). Failure to do so will result in a build up of sediment particles blocking the filter, reducing the fuel flow. This is especially so on older vehicles where corrosion takes place within the fuel tank and metal feed pipes. In order to ensure that the fuel feed system operates at its full potential, it is recommended that both of the above items are checked, and/or replaced, before fitting a new fuel pump.

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The in-line fuel filters fitted to fuel delivery modules in Freelander 2.5-liter KV6 gasoline vehicles may be manufactured away from specification. The fuel filters may contain an uncontrolled amount of the adhesive used to bond the filter paper to the filter casing; the adhesive may not have been adequately cured; or the fuel pump inlet stub pipe hole on the fuel filter may have inadequate dimensional controls. In any of these cases, it is possible for these conditions to prevent adequate fuel flow through either restrictions in the filter or cracking of the pump stub pipe. This leads to increased pump motor use to maintain the required engine-demanded fuel and premature wear of the fuel pump motor brushes. In the event of restricted fuel flow, the vehicle may suffer one or more of the following symptoms: rough running and malfunction indicator lamp (MIL) illumination; poor / no start; engine stumble or hesitation; or engine cut-out / stall with the possibility of Diagnostic Trouble Codes (DTC) P0301, P0302, P0303, P0304, P0305, P0306, P0171, P0174, or P0316 stored. Action: Refer to the Repair Procedure outlined below to replace the fuel pump module. CAUTION: A Midtronics PSC-550 Vehicle Power Supply must be connected to the vehicle battery during IDS diagnosis / module programming. 4. Connect the Midtronics PSC-550 Vehicle Power Supply to the vehicle battery. CAUTION: IDS with T4 software DRG TL 36 5. Connect T4 to the vehicle and begin a new diagnostic session. 6. Select ‘System Diagnostics’. 7. Enter ‘Make and MY’ and correct VIN for the current vehicle. NOTE: Any DTCs not listed in step 3 are to be investigated / repaired as a separate repair. 8. Select ‘Fault Code Diagnostics’. 9. Read and clear stored fault codes. 10. Exit the current session when the task is completed. 11. Disconnect T4 and the Midtronics PSC-550 Vehicle Battery Supply from the vehicle. [NEW] REPLACE FUEL PUMP MODULE – 2002MY WARNING: Place the vehicle in a well ventilated, quarantined area and arrange ‘No Smoking / Petrol Fumes’ signs about the vehicle.

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Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step #2 b. No >> proceed to Step #4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step #4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half’s of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step #7 b. No>> Proceed to Step #11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. 11. Disconnect the control valve to EVAP canister tube at the fuel tank. -3- 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to Step #14. 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube.

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WARNING: Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also Irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing. CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material. 1. 2. 3. 4. 5. 6. 7. 8. Level the vehicle. Complete the “BEFORE REPAIR PROCEDURE”. Disconnect the negative battery cable. Remove the rear seat cushion. Remove the service hole cover. Remove the fuel pump unit. Siphon the fuel from the fuel tank. Remove the presilencer. 9. Remove in the order indicated in the table. 10. Install in the reverse order of removal. 11. Complete the “AFTER REPAIR PROCEDURE”. Plastic Fuel Hose Removal Note CAUTION: The retainer must be replaced If removed from the fuel pipe without using the SST. Otherwise, effectiveness of the retainer will be reduced. 1. Inspect that the quick release connector joint area is tree of foreign material. 2. Clean as necessary. 3. Set the SST as shown and push into the quick release connector to disconnect the plastic fuel hose. 4. Cover the disconnected quick release connector and fuel pipe to prevent them from being scratched or contaminated with foreign material.

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WARNING: WHEN DRAINING FUEL FROM THE FUEL TANK, KEEP SPARKS, SMOKING MATERIALS, AND OPEN FLAMES AWAY FROM THE VEHICLE. WARNING: THE FUEL SYSTEM CONTAINS PRESSURIZED FUEL AFTER THE VEHICLE IS SHUT DOWN AND WILL MAINTAIN THE PRESSURE FOR A LONG PERIOD OF TIME. 1. Relieve the fuel pressure; refer to Section 310-00. 2. Disconnect the battery ground cable (14301); refer to Section 414-01. 3. Raise and support the vehicle; refer to Section 100-02. 4. Disconnect the fuel tank filler pipe hose (9047) from the fuel tank (9002). 5. Drain the fuel from the fuel tank (9002); refer to Section 310-00. 6. Disconnect the fuel tank vent tube (9A228) from fuel tank filler pipe (9034). 7. Disconnect the fuel pump electrical connector. 8. If equipped, remove fuel tank skid plate. 1. Remove the five fuel tank skid plate bolts. 2. Lower the fuel tank skid plate. 9. Position a suitable jack under the fuel tank (9002). 10. Remove the front fuel tank support strap (9092). 1. Remove the two bolts. 2. Remove the front fuel tank support strap (9092). 11. Remove the rear fuel tank support strap (9092). 1. Remove the three bolts. 2. Remove the rear fuel tank support strap. 12. Partially lower the fuel tank and disconnect the two EVAP emissions hoses. 13. Remove the two safety clips from the fuel lines. 14. Disconnect the fuel lines from the fuel pump (9350). 1. Install and push the (A) fuel line disconnect tool into the (B) female fitting. 2. Separate the male and female fitting. 15. Remove the fuel tank. 16. Remove the fuel pump. 1. Remove the fuel pump locking retaining ring (9C385). 2. Remove the fuel pump and discard the O-ring. Installation 1. Install the fuel pump (9350). 1. Install a new O-ring and fuel pump (9350). 2. Install the fuel pump locking retainer ring (9C385). 2. With a suitable jack, position the fuel tank (9002). 3. Connect the fuel lines. 4. Connect the safety clips. 5. Connect the EVAP emissions hoses.