Thread: TD5 fuel regulator hose leak repair

Hi everyone and G'day from Adelaide. Being a relatively new proud owner of a D2 TD5 it's been an exciting introduction to the problems that come as part of package with any 'new' car. I've have loads of experience with man machine battles, previous 4x4 was a Ford Explorer..............nuff said!


I decided that as I gain so much info from owner forums that it's about time I gave back. This is my very first post, where better to start than one of the TD5 'sleepers', the fuel regulator hose leak. I know that the way I carried out the repair may not be the best but it got the job done and was relatively painless, the sort I like!


The full story is in the attached pdf file, with all the pics.

REPLACING THE FUEL REGULATOR TO COOLER HOSE


DISCOVERY 2 TD5 2003




It all started with the engine suddenly losing all power and misfiring . Having made an unplanned stop at the side of the road, bonnet up and wondering what the issue was, a 'knowledgeable' passer by promptly informed me that the misfire was due to one of the spark plugs was fouled. I kindly told him that it was a diesel engine...........”yeah mate, but it's still got plugs”. Having ruled out spark plugs I came to the conclusion that it was lack of fuel. Unscrewed the fuel filter from under the rear offside wheel arch, no fuel!! Using a tried and tested method I lifted the carpet above the fuel tank and hit the top of the fuel pump with something heavy. The fuel pump promptly started and hey presto the thought of getting home again was a reality.


A strip down of the fuel pump didn't reveal anything obvious apart from old age. A new non genuine pump was purchased, fitted and the Disco had more power than it had ever had (in the brief three months since I bought it). Two days later I could smell diesel as I drove along........must have forgotten to properly tighten the fuel pump ring was the first thought. The trail of diesel on the road and a healthy anti corrosion coating along the underside of the body indicated otherwise!! On lifting the bonnet everything was being sprayed with diesel from a pinhole leak on the fuel regulator hose. Back home again, this time thanks to the RAA. A new hose was ordered from the UK (worked out about $35 including postage), and so the task of replacing the hose began.


Here's where the leak was, very messy!!

F4a.jpg


The easy end of the hose to disconnect, assuming that you have a set of crows foot spanners to hand.
F3a.jpg


Now for the unbelievable task of figuring out how to get to the front fitting, where is it!!!!
F5a.jpg


If you read the pdf file you'll see how I sacrificed one of my trusty old ring spanners to create yet another toolbox special. This enabled me to get at the front fitting, after removing the minimum amount of gubbins (don't like losing too many parts).

F6a.jpg


Here's the pdf file, makes more sense.
001 Fuel regulator line replacement.pdf


I hope that it proves of some help for those of you who are looking to get the job done as easily as possible. As I progressively move on through the list of jobs to do on my TD5 I'll try to post similar 'Bodgit & Scarper' guides for a laugh if nothing else .
Cheers
Doug

ps long live the Nanocom Evolution, what a great tool.

Thanks a million - I just had the exact same problem. On the way home I started to smell diesel. Got home and noticed a trail of diesel on the road. Looked under the disco and leaking huge amounts of feul. Looked under the bonnet and noticed fuel gushing out of the section of the connection that was crimped - exact same spot as yours. Once again - thank you.
Cheers,
BoneMan.