Disco 2 td5 rear fuel pipes leaking - change without dropping tank?

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Ush

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Bristol, UK
Hi all, coming back from a round of golf a couple of days ago to find a trail of diesel behind my disco and a puddle underneath. Doesn't leak when engine not running, but when it is, I'm getting a steady stream from rear of the tank, flowing down through the frame rail.. 5 mins of online research suggests pretty strongly it'll be one of the fuel lines from pump, probably the green one?.. have already rung Land Rover to see if the recall is outstanding, but they say no, so I'm going to have to get my hands dirty! I've pulled back the carpet to get to the pump, but question is; how easy is it to replace without dropping the tank? (I've just filled it up and haven't easily got anywhere to put 100l of diesel). It looks like all 4 pipes are secured together, so guessing I can't just extract the green one on its own?.. Whether I replace just the one, all 4 or use a 8mm pneumatic straight connector to repair, will depend on how much effort it is to get them out and back in?
Sounds like a fairly common one, so hoping there'll be a few on here who will have done it various ways and can tell me the easiest / best way to approach.. Thanks all!
 
Easier job on a disco than the Defender, tank has to be dropped in the defender, not so with the disco as far as I'm aware and as you say, it has a hatch above the pump in the boot.
 
Biggest pain is getting all the gear out of the boot to lift the carpet, unless you can't be bovvered and just cut it!
Had to do this recently as my tank had to come off when the chassis was welded.
You might want to purchase a trim removal kit if you ain't already got one.
 
Stanleysteamer said:
Biggest pain is getting all the gear out of the boot to lift the carpet, unless you can't be bovvered and just cut it!
Had to do this recently as my tank had to come off when the chassis was welded.
You might want to purchase a trim removal kit if you ain't already got one.
Click to expand...
What an ass I am, you've already done this. I'll get my coat!
 
Hi, thanks for the replies so far.. I've already accessed the top of the pump so I can disconnect the pipes either end. It's really the question of whether you can remove the pipe clips from the cross member without dropping the tank which is the crux of the issue. I know some people say it can be done.. But not sure how you go about it? Cheers
 
Ush said:
Hi, thanks for the replies so far.. I've already accessed the top of the pump so I can disconnect the pipes either end. It's really the question of whether you can remove the pipe clips from the cross member without dropping the tank which is the crux of the issue. I know some people say it can be done.. But not sure how you go about it? Cheers
Click to expand...
Right, I may get shot down for this but here goes.
If you cut the pipe either side of the clip you may be able to pull the two halves out, if you then can see what you are doing, which may be tough, but with a mirror and a good light?...You may be able to effect a repair then slot the pipe back through.
OR make two repairs one each side of the clip
OR reroute it to avoid the clip issue and secure it another way.
This is all in case you can't lever it out of the clip and back in again. No idea if the clip is open or not.

As I am a lazy barsteward I always try to think out of the box if the pukka route is a pain.

But some will call this a bodge. Fur enuff!;)
 
Its possible to do without dropping tank your sweat jar will be full mind
Unclip pipe from pump and fuel line from chassis leg tape or tie some string to pump end to pull new pipe back through
A long screwdriver or brute force will free pipe from clip and pull out under car
Tie rope to new pipe and use it to guide wriggle it through and refit it took md about half hour
 
Might be worth giving that an hour before I give in and drain the tank! If I can get it loose from the clips then, does that mean the clips are open ended and I can just remove the green one?
Thanks
 
no drain on the tank, I had a full tank jacked the car up on the fill side the removed the fill hose from the tank and syphoned it all out , 100ltr worth, I manged to get a new empty 200 ltr/45 gallon steel drum to put the syphoned fuel in free from my local garage who had lots of them sitting around
 
Last edited:
Great advice to get me started chaps.. Much appreciated! Think the plan then is to spend an hour trying to free pipes from clips and if I can then have a go at pulling them through with a guide wire attached. If it doesn't go to plan, I'll drain the tank via the removed fuel pump or the filler pipe and do it the "proper" way.. But not before Thursday cause I'm getting a couple more rounds of golf in before then! Thanks again, I'll update when I've hopefully sorted!
 
by the way when I syphoned out my tank i used about a1/2in clear plastic pipe , I also put a 2 nuts on the end to stop it floating up and stay on the bottom of the tank, it worked well as when i took the tank down it only had about 1.5 ltrs left in it
 
I did this (novice) on my 2003 Disco 2 Td5 - replaced the green pipe - was quite easy! The pipe I bought came with an anti-chafe sleeve, but to make doubly sure there was no chaffing and subsequent pinhole in the fuel line, I bought a special tape that sailor's use (anti-chafe tape) off eBay and wrapped that around a decent section of the line. Line had previously been replaced three times! Decided to do it myself this time and do it right! Rolled the carpet back (no need to remove any trim as the carpet had obviously been rolled back before by the dealer) easily. Tied a piece of fishing line to the ABS fuel pipe to help pull it through above the tank and up to the pump. Connected to the pump and connected to the fuel filter. Took about 45 minutes - just be reasonably careful with pump connection.
 
Ooh, last 2 replies correct for me too, but a day late! Yup, was actually fairly easy to get carpet up and green pipe out. I slackened of the rear of the tank support to give me a little more access and got the green pipe off (with guide wire attached) inside of 10 mins.. pin hole in it as you would expect. Unfortunately, expecting this to fight me and probably needing to take the tank out, I'd bought all 4 pipes for more than £100! Luckily I've not even opened them yet, so they're going back in favour of £40 for just the green one, but I'll give a final update after that arrives in the next few days. Cheers to everyone for advice, I've read a lot of different experiences for this, so I wonder whether it's different depending on if the jobs been done before. my carpet only just goes under the side trim so was easy to get up. Not sure if that means it's been cut, but you can't tell.. and the pipe easily popped out of the open clips, where many people have said it was pretty difficult. Guess the moral of the story is to spend a little time having a go, before you go buying bits! All that said, I haven't refitted yet so there's a chance it will still fight me!
 
Ush said:
Ooh, last 2 replies correct for me too, but a day late! Yup, was actually fairly easy to get carpet up and green pipe out. I slackened of the rear of the tank support to give me a little more access and got the green pipe off (with guide wire attached) inside of 10 mins.. pin hole in it as you would expect. Unfortunately, expecting this to fight me and probably needing to take the tank out, I'd bought all 4 pipes for more than £100! Luckily I've not even opened them yet, so they're going back in favour of £40 for just the green one, but I'll give a final update after that arrives in the next few days. Cheers to everyone for advice, I've read a lot of different experiences for this, so I wonder whether it's different depending on if the jobs been done before. my carpet only just goes under the side trim so was easy to get up. Not sure if that means it's been cut, but you can't tell.. and the pipe easily popped out of the open clips, where many people have said it was pretty difficult. Guess the moral of the story is to spend a little time having a go, before you go buying bits! All that said, I haven't refitted yet so there's a chance it will still fight me!
Click to expand...

Wasn't this a LR Recall? If so, then 2nd and subsequent times you would be able to roll the carpet back (with strong hands!) without taking any trim off. Anyway, mine was easy, only did the green line - from what I read that is the only one that keeps getting chaffed!
 
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Yup...Was a recall, first thing I did was to ring main stealer and ask if mine was outstanding, but no such luck. As it happens, the pipe arrived about an hour ago and it took me all of about 10 minutes to refit using the wire I'd pulled thru as I'd removed the old one. So all in all took me about 30 minutes in total including getting the carpet up. As I say, I can't guarantee anyone it will be as easy for them.. But definitely worth having a go, before committing to removing trim for the rear carpet or dropping the tank out! Worth slackening the 2 15mm nuts on the tank bracket closest to the pipe you're trying to replace, to give you that fraction more clearance to get the pipe out though.. Cheers all!
 
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