Refitting 2003MY 110 Td5 fuel pipe problem

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Rob K

New Member
Posts
3
Location
Zeist, NL
Defender Td5 110 2003MY

The fuel feeder (fuel tank > engine) pipe of my Defender was scrubbing against one of the mounting brackets welded on the chassis. This caused a leak and I had to replace the whole line from the tank to the engine :(.

As the new line comes with all quick release connectors already mounted, I now have the following problem: The space between the chassis cross member (the one just in front of the fuel filter) and the upper body is not large enough to allow the connector through this space. When removing the old line I just cut it. But feeding the connector through the gap does not work as the gap is just too small. What to do? Raise the body 5 mm from the chassis to widen the gap? That's a lot of work. Is there another method while leaving the expensive replacement fuel line intact?

See picture (I temporary led the line below the cross member, but it has to go above, between the cross member and the body).

Anyone having experience with this?

Kind regards

Rob
 

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Defender Td5 110 2003MY

The fuel feeder (fuel tank > engine) pipe of my Defender was scrubbing against one of the mounting brackets welded on the chassis. This caused a leak and I had to replace the whole line from the tank to the engine :(.

As the new line comes with all quick release connectors already mounted, I now have the following problem: The space between the chassis cross member (the one just in front of the fuel filter) and the upper body is not large enough to allow the connector through this space. When removing the old line I just cut it. But feeding the connector through the gap does not work as the gap is just too small. What to do? Raise the body 5 mm from the chassis to widen the gap? That's a lot of work. Is there another method while leaving the expensive replacement fuel line intact?

See picture (I temporary led the line below the cross member, but it has to go above, between the cross member and the body).

Anyone having experience with this?

Kind regards

Rob

There should be a “notch” in that crossmember, just above the drivers side chassis rail. I’m not sure exactly how big it is as I don’t have the rear floor section installed in mine. Give that a try, if it doesn’t work, remove the two bolts in that body/chassis mount, and “lever” the rear floor upstand up slightly.
 
Last edited:
Thanks Mick
Yes, there is a notch, but it is too small for the quick release connector. IMHO the only way is to lift the body half an inch.
Rob
 
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