Split Spill Return Hose 300 tdi 1994

I am an utter novice with an 18 year old, 137000 mile, Defender 300 tdi. Today I noticed what I think is called a spill return hose - the 'woven cloth' hose between the injectors - that has split and therefore spilled a tiny amount of diesel. I haven't driven it since. Question/questions, my 4 x 4 garage is 4 miles away is it safe to drive that short distance or should I get it towed via the AA - I have wrapped a bit of cling film around the pipe to stop dirt getting in too. What is your opinions? Ie how serious is this if I drive it? I welcome all opinions as I am very much a novice (Haynes Manual one spanner man) so please write it in as simple a way as possible - I won't be offended I can assure you all. Thank you from Penn, Bucks, England.

No worries, first of all it'll be a seep not a gush and then it's diesel not petrol so it's not going to ignite easily.

However, as you say, it's only a bit of pipe. With a little care as you pull the old one off, or run a sharp knife ALONG the pipe to split it, and you could just buy a length of pipe and replace it yourself. If one's gone you're probably as well to replace the lot.

Thank you Dogsbody. I am not keen on trying it myself so will get it to the garage and have them all replaced. So as you wrote, does this mean that the vehicle will start ok and that I should be able to get it the 4 miles to the garage, all things being equal? Should I wrap a bit of cling film around it too for the duration of the trip? What is the purpose of these pipes and why are they made of what looks like a dense woven cloth? I did warn you all that I am at the bottom of the food chain vis mechanics. Thank you again though.

Mike Wingert said:

Thank you Dogsbody. I am not keen on trying it myself so will get it to the garage and have them all replaced. So as you wrote, does this mean that the vehicle will start ok and that I should be able to get it the 4 miles to the garage, all things being equal? Should I wrap a bit of cling film around it too for the duration of the trip? What is the purpose of these pipes and why are they made of what looks like a dense woven cloth? I did warn you all that I am at the bottom of the food chain vis mechanics. Thank you again though.

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There's no harm in trying it yourself. It is a very straight forward task involving three short lengths of rubber fuel hose which are just pushed over flared banjo fittings on the injectors. The cloth that you see is braided over the top of the rubber pipe just to make it a little harder wearing. These pipes are commonly referred to as the "spill rail" or the "leak-off". Essentially all they are doing is returning the excess diesel that is pumped to the injectors to help lubricate and cool their internal components back to your fuel tank. They are not under much pressure. You might find that it takes five or six turns to start as opposed to one or two because air will have slowly worked its way into the fuel system. This won't be a problem in the short term but if it was left like this for an extended period of time (a few months) then you would run the risk of damaging your injectors as they have to prime themselves on every startup). Wrapping it in cling film wouldn't cause any harm but it seems a little excessive.

-Tom

POS. Thank you very much. I feel much relieved by that explanation. Although I have had the Landy from new it is very much used for running around in and is a complete life saver where I live when we get snow and for taking animals to the vet. It has never been off roaded even. I intend to make it last forever! Thank you all again, this is a great site and perhaps one day I might be able to help someone with even less knowledge than me!

Bought the hose, £4.50 a metre at Dingocroft in High Wycombe and then cut it and fitted it. What a stupidly easy job and what a flap I got into! Thank you all for the advice and giving me the confidence to do it myself - saved a garage bill too.

Mike Wingert said:

Bought the hose, £4.50 a metre at Dingocroft in High Wycombe and then cut it and fitted it. What a stupidly easy job and what a flap I got into! Thank you all for the advice and giving me the confidence to do it myself - saved a garage bill too.

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Hey, good for you Mike.

p.s. My sister lives in St. Johns Road!!