TD5 diesel leak

My 2003 TD5 has developed a diesel leak. First investigations indicate that its coming from (bear with me on the description as I couldn't get a photo!) a small item at the back of the engine. Basically behind inlet port 5 (the last one counting from the front) at about the same level there is a small casting that has a number of diesel connections going to it and coming out of it. One seems to be the return to the tank, another returns to the cannister below the inlet manifold (no idea what that does) and another returns to the front of the inlet manifold.

Any ideas what this does / does anyone have an engine out that I could have a pic off? Any help on where it might be leaking would also be useful if its a known fault.

Thanks guys

It's the fuel pressure regulator, it's a known fault, and it's an OK job to fix.

If you don't have RAVE manual, get it before you start.

Here's an example of RAVE. You just got to get a copy - search Landyzone for it FREE!

RAVE SAYS ............. (pictures aren't so easy for me at least!)
REGULATOR - FUEL PRESSURE
Service repair no - 19.45.06
Remove
1. Remove 3 bolts and remove engine acoustic
cover.
2. Remove battery cover
3. Disconnect battery negative lead.
4. Release hose from fuel cooler.
5. Release fuel hoses from pressure regulator.
6. Disconnect multiplug from fuel temperature
sensor.
7. Remove 3 bolts, remove pressure regulator from
cylinder head and collect gasket and ’O’ring.
8. Remove fuel filter from cylinder head.
9. Remove fuel temperature sensor and discard
sealing washer.
10. Remove fuel hose and fuel pipe and discard ’O’
rings.

Job done

Refit ....

11. Clean fuel pressure regulator, mating face and fuel filter.
12. Clean fuel pipe unions.
11. Clean fuel pressure regulator, mating face and
fuel filter.
12. Clean fuel pipe unions.
13. Fit fuel pipe and fuel hose to pressure regulator using new ’O’ rings.
14. Fit fuel temperature sensor using new sealing washer and tighten to 14 Nm (11 bf.ft).
15. Fit fuel filter to cylinder head.
16. Using a new gasket and ’O’ring position
pressure regulator and tighten bolts to 25 Nm
(18 lbf.ft).
17. Connect fuel temperature sensor.
18. Connect fuel hoses to pressure regulator and
fuel cooler.
19. Fit engine acoustic cover.
20. Reconnect battery negative lead.
21. Fit battery cover.

Thanks Charles. That is very helpful. I'll get the service pack and let you know what happens.

Can't find the RAVE CD for the TD5 - all I seem to keep getting is the older version. I'll keep looking.

Any idea where I can get a repair kit for this item. Seems silly to pay £90 for 4 'O' rings and a paper gasket - particularly when the manual says that its a serviceable part!

jonnyt said:

Thanks Charles. That is very helpful. I'll get the service pack and let you know what happens.

Can't find the RAVE CD for the TD5 - all I seem to keep getting is the older version. I'll keep looking.

Click to expand...

Somewhere in Landyzone .... but I know not where!

jonnyt said:

Any idea where I can get a repair kit for this item. Seems silly to pay £90 for 4 'O' rings and a paper gasket - particularly when the manual says that its a serviceable part!

Click to expand...

If it ONLY needs 4 O-rings and a paper gasket, buy a tray of O-rings from Macnine Mart etc for a fiver, and buy some gasket paper and a tube of blue Hylomar.

CharlesY

BTW - this is the only link for the TD5 that I found that worked / wasn't in German!!

http://green-oval.com/joomla/index.php?option=com_docman&task=cat_view&gid=13&Itemid=29

Never had much luck with the cheap 'O' rings - they have always had a tendency to breakdown pretty quickly in my experience. I've ordered a regulator anyway now - I'll change it and then re-con the old one and put it back into stock. It sounds like its a pretty common fault so the chances are it'll happen again on one of them.

Thanks for the help.

jonnyt said:

Never had much luck with the cheap 'O' rings - they have always had a tendency to breakdown pretty quickly in my experience. I've ordered a regulator anyway now - I'll change it and then re-con the old one and put it back into stock. It sounds like its a pretty common fault so the chances are it'll happen again on one of them.

Thanks for the help.

Click to expand...

I could post you a CD of RAVE if you're stuck.
PM me an email and snail mail address if you need to go this way.

Meantime phone a main stealer and ak what will charge to supply and fit a new fuel pressure regulator. Your £90 is going to look puny compared.

CharlesY

Thanks for the offer Charles. As I said though I finally found that link that I posted in the last reply and that seems to work although it is not particularly reliable (although that may be my slightly old computer at work).

Thanks again for all your help and words of wisdom. We'll see how I get on fitting it. I can't imagine for one moment it will be as easy as the manual makes out!

The only thing that the parts place did say was that the problem tends to be a mechanical one with the casting rather than just o-ring or gasket. I'll update once I've got the old one off.

If you do fit the new part don't throw away the old one.

There's a comany up here can deal with dodgy castings like that. They used to do (might still for all I know) all the wee carb castings for Ford factory in Belfast (1976!) and we carried the crates of parts from Belfast to Vacuseal and then took them back to Belfast. Nice work.

They might well be able to vacuum dip and resin impregnate the fuel regulator for us. It all depends on whether there are tiny passageways involved than might need drilled out afterwards. I don't think there are.

ALL dodgy light metal ("Dinky Toy metal") die-castings can be treated this way.

CharlesY

Vacuseal Ltd
88 Greenhill Road
Paisley
PA3 1RD (Road Map)
Renfrewshire

Tel: 0141 840 1301
Fax: 0141 8878355

How did you get on with this????

Mines just started pishing derv everwhere I knew it was only a matter of time.

I was always under the impression that you had to change the whole unit??

Hi Jason,

I have to admit that I've changed it and haven't had a chance to look at the old one properly let alone recondition it. There was no obvious problem with o rings and the gasket is a metal item as far as I can remember. I couldn't find a repair kit anywhere for it.

I'll have a look at the old one later and report back if I can see anything obvious.

Jon

jonnyt said:

Hi Jason,

I have to admit that I've changed it and haven't had a chance to look at the old one properly let alone recondition it. There was no obvious problem with o rings and the gasket is a metal item as far as I can remember. I couldn't find a repair kit anywhere for it.

I'll have a look at the old one later and report back if I can see anything obvious.

Jon

Click to expand...

Cheers Jon

That would save me farting about trying to find a repair kit that dunt exist.

I believe you need small fingers to change it? I'l get the wife to change it then

Jason

Jason,

Had a look at it over the weekend. Can't see anything obvious. The rate at which it leaked from nothing to pouring out (a week or so) I'd guess the problem is in the regulator looking thingy at the end. There might be some seals in there but no idea how to change them. I don't think its either 'o' rings (there ain't any that create a seal) and the metal gasket had no signs of a leak.

Not too bad a job to replace once you've worked out how the pipes come apart with different fittings on every one as I remember. As far as I recall though I didn't strip anything down and it wasn't a huge task.

HTH,

Jon

Cheers Jon

I will get a new one ordered as soon as possible, only at the few drops leaky bits at the moment.

Jason

anyone got any further details? photos? on this mine has just started ****ing out :-(

I got a new one frrom paddocks for about 80 snakes (was chuffed too as it was a genuine LR part or at least the box was ) There are 2 types, early ones have 2 pipes later ones have 3. Don't forget to get the gasket and O ring.

Easy to change, you need a very small socket set & stick gasket to regulator with grease to stop it dropping off.

Some reckon that you can repaire them?

Jason2 said:

I got a new one frrom paddocks for about 80 snakes (was chuffed too as it was a genuine LR part or at least the box was ) There are 2 types, early ones have 2 pipes later ones have 3. Don't forget to get the gasket and O ring.

Easy to change, you need a very small socket set & stick gasket to regulator with grease to stop it dropping off.

Some reckon that you can repaire them?

Click to expand...

Sadly, it seems the leaks occur THROUGH a diaphragm which fails, rather than because o-rings start leaking.

I took my one to bits, easy job, but as far as I know getting spares for them is next to impossible.

CharlesY