Learning Puma the hardway

**FV1601** · 17th January 2016, 08:47 PM

Visit to the Vic High Country today, halfway down long slow descent into Glen Dart to find the truck (MY2010 130) was not actually running, engine was turning only due to the hill. All appeared as it should be, keyed over OK, no start, not an immobiliser issue this time, back to basics.
Look underneath to find fuel line has snapped off the plastic quick connect, where it runs through an ally box (No idea what that's for) on the side of the chassis rail. Steal some fuel line and hose clamps off the mod for the long range tank (removed before my time) to repair line, whittle some green sticks down to plug now exposed breather's. All good, fortunately I had quizzed the dealer mechanic about bleeding, so disconnected the line as shown and pressurised the tank with the air compressor. Took me some considerable time to work out that I was working on the return line, not the feed, possibly not helped by the explanation of the use of a Genuine Part, a bulb, being used to suck the fuel through.
Disconnected line at fuelrail, pressure tank, fuel present, Disconnect after fuelrail, pressure tank, fuel present. No start.
Plan was to roll on down the hill till we could park safely and walkout, no phone coverage of course. Rolled in gear for 2-300m. and shocked to realise that motor was now running fine. Stopped while still on the hill to try a key start, no probs.
Way out was up some good low range climbs, but no mood to enjoy them as confidence was low..
Fix still holding when we hit bitumen in the Nariel Valley, and all the way home, 180kms?
Need I mention that the roll of fuel hose that has been in the back of the truck for ages was removed yesterday for some remedial work on the Austin Champ....
Cause of this saga would have been simply a stick catching where it shouldn't have, but I would really like to meet the numbnuts who designed this set up, unprotected hoses and brittle plastic connectors.
I would advise anyone who goes bush to have a couple of these connectors on standby, I assume you can buy them somewhere, personally I will be modifying them out of the system, and investigating fabricating some sort of protection.
Still, the two of us got home without walking, not always the case, and we get to go back next week to finish of the trip.
Rich.

**MLD** · 17th January 2016, 09:19 PM

Very few 4wd trips I've been on were event free. At least it was one of the events that are not a risk to life or limb. Congrats on the bush mechanics and driving out. Aaarrrrrhhhhh the joys of defender ownership. It's a love hate relationship.

Yes I agree that the fuel cooler is in a bad location.

MLD

**Toxic_Avenger** · 17th January 2016, 09:24 PM

Sounds like the fuel cooler?

There was a run of bash plates made by Pete simpson which protected said component. I run one of those.

APT also make a cage type unit that protects it.
Might be worth considering if you were going to invest the time into designing / making one from scratch?

The fuel cooler is in a dicky position, but nevertheless, good work in getting out safely.

**FV1601** · 18th January 2016, 05:06 PM

Thanks guys, certainly would not be the first time I have had to leave a vehicle behind...Left a SII shorty on Wombat Spur for a week, and Mayford come to that, the F100 in Miners Flat, and the list goes on. But these days I am older, and I thought wiser, maybe not.
Found the APT guard:
Land Rover Fuel Cooler Guard | Defender TDci - APT Fabrication Custom Land Rover Parts & Accessories
looks like a worthwhile investment.

I notice that the box is indeed referred to as a fuel cooler? I would have thought it was a fuel heater as it appears to be plumbed into the radiator, and as such would have hot water pumping through it. Anyhow, that means there are two coolant lines waiting to be yanked off by an errant stick as well.
Rich.

**Toxic_Avenger** · 18th January 2016, 05:27 PM

Originally Posted by FV1601

I notice that the box is indeed referred to as a fuel cooler? I would have thought it was a fuel heater as it appears to be plumbed into the radiator, and as such would have hot water pumping through it. Anyhow, that means there are two coolant lines waiting to be yanked off by an errant stick as well.
Rich.

Cooling is relative

Under most situations, yes, heat flows from the engine coolant to the fuel. Under the conditions when the fuel needs to be cooled, it would be working the other way.
My understanding is that it has to do with keeping the diesel away from its flash point / auto ignition temp.

Yes, It's a liability waiting to happen. If it can be safely turfed, it'd be a good spot to cobble up some kind of hot water shower setup. Not sure what kind of heat exchange ability it would have though...

**ozrob** · 18th January 2016, 07:17 PM

Yep the same thing happened to me down the farm, a log took out the fuel heater, I had some spare fuel hose from my long range fuel tank breather and fixed the fuel pump return line back to the tank.
Technically I believe that the item in question is a fuel heater which in cold countries is used to warm the fuel in the main tank to engine temperature so that the fuel has a consistent temperature. This prevents the diesel fuel from waxing once you are driving in the minus temperatures and provide a consistent flow rate through the fuel system.
So in Australia where we have high ambient temperatures is it cooling or heating the fuel? I have not checked the temperature of the fuel as it leaves the tank, however i have not noticed and difference in vehicle performance.

**AndyG** · 18th January 2016, 08:12 PM

I have the Apt fuel cooler guard, it's it's a nice bit of kit.
I thought

it was to cool the return fuel after being through the high pressure circuit

**DazzaTD5** · 19th January 2016, 10:40 AM

Originally Posted by AndyG

I have the Apt fuel cooler guard, it's it's a nice bit of kit.
I thought

it was to cool the return fuel after being through the high pressure circuit

Thats correct, its the return line, keep in mind as with any common rail diesel, return fuel is a constant flow back to the tank and is hot after going through the high pressure pump / rail assembly. You will find most common rail diesels have a fuel cooler.

And ripping the lines off the cooler is also a common Defender TDCi thing, sort of a bad spot, but as mentioned the APT fuel guard is the way to go...

Regards
Daz

**Avion8** · 20th January 2016, 12:22 PM

Thanks for posting this up. I did check the APT website & it mentions that not all 2.2 TDCi's have a fuel cooler, so checked under mine & it does. So ordered the APT guard today, great service as it is already on the way with tracking numbers.

**FV1601** · 20th January 2016, 04:37 PM

Also ordered my APT guard today, included a steering guard as well in the hope that a bit of stick may have a harder job in disabling the pinnacle of 70 years of off-road design.
If I understood the reasons for the cooler more fully, I think I would be removing it.
Be nice to think that my misfortune may prevent someone else's!
Rich.

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