Learning Puma the hardway

[FV1601]

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]

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]

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]

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 (http://aptfabrication.com.au/land-rover-fuel-tank-guards/product/290-land-rover-fuel-cooler-guard-defender-tdci/category_pathway-38)
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]

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]

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]

I have the Apt fuel cooler guard, it's it's a nice bit of kit.
I thought :confused: it was to cool the return fuel after being through the high pressure circuit

[DazzaTD5]

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

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]

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.

[ozrob]

Thinking more of the is it a cooler or a heater???
Depending on the temperature of the excess fuel as it leaves the high pressure pump, as it enters the cooler/heater it is at least cooled/heated to engine coolant temperature 70 odd degrees as the coolant lines come from the bottom of the radiator, then back to the tank.
At rest the fuel in the tank can't get any hotter than ambient surrounding air temperature so there is no risk of high flash point, not that it is a problem with diesel fuel.

[Gerokent]

Same thing happened to mine about 5 years ago, a blade of grass took out the plastic coolant hose. Got rid of cooler and ALL plastic lines and replaced with rubber fuel hose (and fitted a fuel filter with built in hand primer). Beautiful.

[DazzaTD5]

Its a fuel cooler, its purpose/reasons on any common rail diesel is (in the most basic explanation):

*Diesel engine power will be typically measured at fuel temperatures of 50 C (deg C), the higher the diesel fuel temp, the less density it has, less density, less power.
*A typical common rail diesel on the high pressure side of the fuel system will be around 30,000psi, high operating pressures cause excessive heated diesel.
*Diesel fuel is also used to cool (and lubricate) fuel system components, so the fuel also acts as a heat sink (heat exchange).
*Most common rail fuel systems have a high volume of fuel going through the fuel circuit, aprox 80% of fuel delivered to the engine goes back to the tank via the return line.
*The fuel cooler (heat exchanger) is what removes excess heat from the return diesel fuel, airflow also aids heat dispersion.
*The coolant lines connected to the fuel cooler, or rather the "Heat exchanger" are not at that coolant temperature of 80 - 90 deg C, but (like a lot of the cooling system) are typically round 50 deg C.
*The coolant removes excess heat from the heat exchanger.
*The cooled return diesel fuel can be round 40 deg C.
*The cooled return diesel fuel temperature will be closer to that of the fuel in the tank.
*The less differential between return diesel fuel and whats in the tank reduces the possibility of condensation.
*Cooler diesel fuel improves efficiency in combustion and reduces emissions.
*Cooler fuel in the tank reduces overall tank temperatures, with reduced radiated heat through the body.

Often what seems a basic component with a simple purpose has quite a complicated role with many factors taken into account. This is where mechanical engineers really are worth their wait in gold.

Less worth is the person/engineer that missed such basic items as making a TD5 fan belt that 5mm longer to add installation etc etc...

Hope that helps..
Regards
Daz

[jackdef90]

It helps prevent condensate in your fuel tank aswell, common rails don't like even the slightest bit of water!

[FV1601]

After 11 days with the courier, my fuel cooler cover and steering guard have arrived and been fitted. Quality of design/materials/precision of the APT Fabrication products is of the highest standard: as a grumpy Fitter/Welder this is hard won praise!
As a side note, on removal of the OE steering protection bar I found that the two outside securing stays were full of rather noxious black water. I would recommend a couple of small drain holes to anyone staying with the standard setup.
Anyhow, hopefully it will be a while before I have another of these Photo Opportunities.
Rich.

[DazzaTD5]

After 11 days with the courier, my fuel cooler cover and steering guard have arrived and been fitted. Quality of design/materials/precision of the APT Fabrication products is of the highest standard: as a grumpy Fitter/Welder this is hard won praise!
As a side note, on removal of the OE steering protection bar I found that the two outside securing stays were full of rather noxious black water. I would recommend a couple of small drain holes to anyone staying with the standard setup.
Anyhow, hopefully it will be a while before I have another of these Photo Opportunities.
Rich.

The OE steering guard is rubbish and always full of that black water.

All APT Fabrications gear I have seen and fitted have always been well made and nicely finished. The APT Steering Guard is another good bit of kit.

Regards
Daz

[AndyG]

I think the black water is factory fitted, had it in week. 1

[Avion8]

Fitted the APT fuel cooler guard yesterday & it fits a treat. Only problem is my floor creeper seems to have grown bigger wheels, as it was a little tight underneath - probably should have jacked the front & put some axle stands in place. Or could have just been Christmas, New Year & Australia Day, only Chinese New Year to pass & I can get back to skinny!:D