Defender Fuel pump replacement woes.

**Mudnut** · 15th January 2015, 04:30 PM

Well I have gone and purchased a fuel pump assembly from the UK, as mine is sounding like an angry mosquito. Now on to the replacement. I have roller draws in the back so cutting a hole to access is very difficult. So thought just drop the tank. Little bit trickier as I have a separate tank in behind the fuel filler, that drains into the main tank, so a little bit of extra plumbing. In the process of lowering the tank, heard a crack. I know from experience that these noises are expensive. Sure enough, broke 2 of the connector ports on the fuel lines, into the fuel pump assembly (black and green). Of course Land Rover does not sell these separately and have to purchase new lines. Really angry, as these are expensive, and it is a stupid design in the first place.
I have located a company in Germany that sells aluminium connectors in a set of 4 for $39 Eruo's plus shipping. Just waiting to find out if they ship to Australia.

What should have been a 2 hour job has now become a 2 week wait if they ship here at all.

Stated 4 bar pressure. Will a couple of hose clamps on the connectors from Germany that are a barbed fitting hold without leaking?

Any help would be appreciated.

Also getting the locking ring off the old assembly seems next to impossible. ended up knocking the whole assembly around without loosening the locking ring. Any tips on getting it off without damaging the old assembly? I would like to keep it as a spare.

Thanks in advance,

Ken

**Scouse** · 15th January 2015, 08:22 PM

Originally Posted by Mudnut

Also getting the locking ring off the old assembly seems next to impossible. ended up knocking the whole assembly around without loosening the locking ring. Any tips on getting it off without damaging the old assembly? I would like to keep it as a spare.

There's a variety of tools available on eBay:
fuel pump removal tool | eBay

**Rurover** · 15th January 2015, 10:06 PM

Ken,
Bad luck about the fuel pump.
From my experience you may not need a new one but may just need to clean the accumulated black gunk from the old pump.
Anyway, you do still need to remove it.
I presume you've tried a chisel and hammer on the locking ring... ok if you are happy to buy a new ring.
Re the fuel hoses and connectors.
I suspect the fuel line connectors you have ordered may be designed for nylon fuel line which just needs to be forcefully pressed onto the barbed end using a caulking gun like device or I understand it can be done using careful application of heat.
Nylon fuel line should be available from industrial suppliers (also used for pneumatic assemblies) or on the Internet.
Good luck,

Alan

**Mudnut** · 22nd February 2015, 05:10 PM

Well came back from holidays, and the connectors arrived while we were away. Was able to press them into place, and put a hose clamp around the line to secure. Note the interior of the line appears to be lined in plastic, so had to make sure it was pushed in correctly, and not bunched up.
Clipped into place easily.
Was able to get the locking ring off the old assembly by knocking it off with a socket extension and a hammer. Needed to put the seal in place first, and then put my knee on the fuel pump assembly whilst turning the locking ring to get it to lock in place. This was then tapped home in the reverse of removing it. Would find it hard to do this through a small trap door in the floor.
Getting the tank in place was a several hour job, as the extra fuel tank and hose made it difficult to line up and install. Finally got it, but was totally exhausted when finished. I am getting too old for this kind of work, 34 degrees, and 90% humidity didn't help.
Had to follow the re priming procedure in the owners manual. Would not start without following these steps. Was such a relief when it finally fired. Saved a packet of money, but cut hands, and sore muscles today are part of the price.
Here are some pics of the connectors. The second photo is upside down.

Cheers,
Ken

**Mudnut** · 22nd February 2015, 05:14 PM

Originally Posted by Rurover

Ken,
Bad luck about the fuel pump.
From my experience you may not need a new one but may just need to clean the accumulated black gunk from the old pump.

Alan

Thanks Alan, tried to clean out the old pump, but was fairly clean. Was a bit of black growth on the outside of the filter, but not enough to obstruct flow. Could not see anything on or near the pump itself. Ended up installing the new one, and keeping to old for a spare.

Cheers,

Ken

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