Fuel leak at top of tank?

[Charles]

Hi Guys,
D2 Td5 has diesel filling the depression on top of fuel tank which the fuel pump sits in. I noticed a leak when tank was full and assumed it was one of the 4 hoses. However, when I pulled the fuel pump cover I saw the "valley" was full of diesel and it was running down side of tank creating the "leak"

I now figure it must be the fuel pump to tank gasket although the locking collar appears to be nice and tight.

Suggestions welcome before I pull it apart any further as I don't really want to do more work than needed whilst away from home.

Cheers, Charlie

[Outback 1]

Could well be one of the fuel lines they are known for rubbing through where they pass between the chassis and the tank

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[Charles]

Hi Ken,
Don't think it's a fuel line given the fuel spill is right up on top of tank (and I have a spare green line just in case and I'm rarely that lucky!). Should have a better idea soon as just about to drop the tank to inspect things properly.
Cheers, Charlie

[Ean Austral]

From memory there is an o-ring where the fuel pump goes in the tank it could be that, but my father in law had his fuel pump leak from where the nipples go in the top of the fuel pump so maybe you have the same issue.


If you can access the inspection cover thru the cargo area you will be able to see the top of the pump plus all the 4 (? from memory ) fuel lines.


Cheers Ean

[Charles]

Thanks Ean, I think this may be a similar issue... amazing how hard it is to see "leaks" when everything has been flooded in diesel!!
Cheers, Charlie

[Ean Austral]

Thanks Ean, I think this may be a similar issue... amazing how hard it is to see "leaks" when everything has been flooded in diesel!!
Cheers, Charlie


It could still be a rubbed thru hose , the down side of the top of the pump leaking where the nipples are moulded is you need to replace the fuel pump.


When we did the canning stock route trip, 1 of the D2's had a leak on the top like you mention and I think it was a loose fuel line, or it had rubbed thru and from memory we sleeved it with some hose.


Cheers Ean

[Pippin]

TD5 Disco Fuel pump/sender unit - Land Rover Technical Archive - LR4x4 - The Land Rover Forum (http://forums.lr4x4.com/index.php'showtopic=54796) There is a more complex rubber seal for the pump than an 'O' ring which is easy to misplace when fitting the pump, this link you will find helpful.
Nick

[Charles]

Tank out and fuel lines are all good. Diesel is leaking out the fuel pump seal if I tilt the tank to immerse it.

Looks like I will be looking for a replacement seal once I work out what is involved.

Pippin, thanks for link.

Cheers, Charlie

[discorevy]

I've seen this quite a few times, people fit the pump with the sealing ring above the receptor and think its really hard to screw the cap down . one half of the sealing ring must go below the receptor, you'll have to clean the area and remove the pump far enough to fit the sealing ring correctly...... Should fix it

[Roverlord off road spares]

I've seen this quite a few times, people fit the pump with the sealing ring above the receptor and think its really hard to screw the cap down . one half of the sealing ring must go below the receptor, you'll have to clean the area and remove the pump far enough to fit the sealing ring correctly...... Should fix it
And some people have stood on top of the pump trying to get the cap to screw on and have broken the pipe outlets.. So don't try and force things.

[Charles]

Hmmmm.... pump is out and seal is hardened but still looks pretty good... knowing my luck it will be the wee little o rings up inside the the outlet assembly where the 4 pipes plug in...

Cheers, Charlie

[discorevy]

If it was those then you would be able to see them leak with pump running.

[Charles]

Hmmm,
Cleaned everything and fitted new seal. Fitting was straightforward with only firm finger pressure required to seat the pump so the collar could be tightened down. No visible damage to tank or pump seating surfaces and seal was correctly situated.
Still have seepage and buggered if I can tell where it is coming from. When I mopped up the diesel in the pump well (about 200ml in 600kms) it looked to weep from around the white plastic tab as shown in photo. Having said that, it is also very "wet" around the 4 pipes and the top of the pump housing.
The 4 pipes are in perfect condition with no visual damage however I can push them 1 - 1.5mm deeper into the connectors than the clips hold them.
I don't see any obvious spray/mist/dripping from the 4 pipes where they clip into the pump housing when pump is running.
Starting to think I will have to replace the pump but don't want to do that if it isn't the cause.
Cheers, Charlie
108465

[Charles]

Hi guys,

Problem now solved with the installation of a new fuel pump. The weeping was from one or more of the 4 pipes where they fit into the moulded nipples on top of pump assembly. The weep / leak was impossible to see, even after removing and cleaning everything then sitting in back watching while car went on a 10 km run. Fuel "appeared" after backing off after a sustained run at 2500rpm so I think it may have been the return line that was leaking.

New pump came with new pipe retaining clips which were much stiffer to engage, so perhaps it was just a case of the old gear just getting a bit loose as they were easy to clip in and out with fingers.

Anyway, if you suddenly have fuel on top of the tank and no obvious source - check your nipples :p

Cheers, Charlie

[rpo83]

Thanks Charles, i'm going through a similar thing now, i'll carefully check the return line..