So when I fill the tank, I get a strong fuel smell. I was thinking rusty lines, but that would be all the time leaking, not just when full. So I pulled the carpet back and took off the cover. The cover screws were almost rusted away, but the rest of the metal looks great. I replaced the screws with new when I put it back together. When I started to clean the top of the pump, my heart sank. The hole top was loose. First thought was someone screwed up and stripped out the tank threads or busted the lock ring. So I remove the fuel lines after spraying some WD-40(had no PB on hand) on the lines. Removed the pump and proceeded to clean. Found solid lines and no damage. Someone had obviously replaced the pump or something and couldn't get the rubber gasket back in place so they said screw it, and left the pump loose in the tank. So tomorrow I get a fuel filter cause I haven't done that yet, and it is prolly full of dirt and crap. Funny thing is, I never got any evap codes...is that normal on Discos? Pics as soon as I downsize them.

 

Might be useful to anyone planning on looking at the lines for rust, or for pump replacement.

 

And a shot of my shop foreman and supervisor.

 

So the gasket was missing?
Weird.

I reused the gasket on my wifes Volvo and I get a large EVAP code all the time and I really dont want to put a new gasket in because it is a station wagon and I have to remove the third seat.

Your '96 does not have advanced EVAP so no EVAP codes.

 

So it is non-AEL...I was wondering.

 

Mid '97 and later is AEL.

 

From looking at the pictures, that is an orignal LR Fuel Pump Assembly. My old one was identical to it except for a nasty crack in the plastic around the return line on mine. I had to replace the entire assembly due to that crack.

I found that trying to put the rubber gasket around the fuel pump and then trying to force it in place just did not work for me. I ended up putting the rubber gasket in place on the opening in the tank first, I then applied a light coating of Vaseline to the inner surface of the rubber gasket and easing the pump assembly into place. It worked very smoothly. And yes, that is a Pre-AEL version we have. I bought a new ProLine assembly from Rovers North for 100 bucks. Works great.

 

Yeah, I have never had any luck installing a fuel pump with the gasket on the pump. Now I just have to figure out why they pulled the assembly without replacing it...Maybe the po replaced the pump and not the assembly...

 

I went back and took a closer look at your pic. The fule pump was definitely replaced. The original is a silver colored cylinder, not the black module in yours.

You can see some pics of mine in the albums linked to my signature.

 

Yeah the "seal ring" as its called has to be put in the the rim of the tank opening, it "clips" into ribs on the tank opening, sits more like a grommet on both sides of the rim. The set up is very similar (almost identical) to my BMW M5. I've never done the fuel pump on my Disco yet but I can see from the pics it's almost the same. Back in July I replaced the fuel pump on my M5, I spent almost 2 hours trying to squeeze the new pump into the tank with the seal ring on the pump, because that was the way it came out. Then it dawned on me that maybe it went into the tank first. I went and read the manual very carefully and the wording says to put the seal ring into the tank rim first, then shove the pump in, how stupid did I feel?!

Anyway back to your original problem, my Disco too makes a strong gas smell when filled up. Has done for a few years now, it's got so bad this past winter it now drips gas when full so I'm going have to fix it very soon. But if replacing the seal ring on your pump doesn't fix it, check this: Next time you fill up, get down on the ground and look up under the body where the filler tube is, close to the filler tube you should see another slightly smaller tube, that I'm assuming is a vent tube. Mine is cracked pretty bad and that's where my gas/smell is coming from. I've yet to figure out where it attaches on to the tank and how easy it is to get to? I was hoping it attached where the cover was so that was why I looked at your pics. But can't see it there.

BTW: nice score on the 96 5spd Disco, there's not that many of those around post 1995 model with 3 pedals.