Thread: 2003 Discovery 2a Td5 Issue.

Originally Posted by Jazzman

Is there any diesel on the rear window or on the back of the car? There is a fuel line that wears though, the green one. Perhaps yours has worn though and this is causing you fuel pressure issues?

The line is on top of the of the tank but is not accessible unless the tank is removed.

I wouldn't remove it unless there is evidence of leaking fuel under the car or on the back door or window.

Hey Jazzman, no fuel leaks, but have had this happen on another one of my Td5 vehicles awhile ago. It still didn't react this way though.

Going to do Injector Seals today or tomorrow, depending on when parts arrive, so will be able to eliminate that or fix the problem hopefully.

Injector seals finally arrived tonight. Will have to wait until Wednesday now to fit them up. Let's hope this will sort it out.
I'll post the results.

Originally Posted by Ean Austral

Its a good idea to sleeve the fuel lines across the top of the tank. You can get to them from the underneath at the front of the tank. Some electric conduit or similar works well and stops down the rubbing.


Cheers Ean

Ean, from the UK recall notice ( Recall Details for LAND ROVER - Discovery Series , Diesel TD5 ) it appears that LR originally fitted corrugated conduit over the plastic fuel lines, as the recall says to remove it.
I am about to replace my green pipe (prev. owner had it replaced also, this one has rubbed through on the fuel filter water sensor wiring plastic sleeve), and my 2/h replacement has a series of transverse wear marks from the conduit corrugations. I bought a full set of pipes from a wrecker, but the green high pressure one is the only one with the corrugation wear marks.
............. I suggest that the high pressure pipe from the pump VIBRATES due to pressure pulses from the pump, thus making it more prone to wear than the other three pipes.
I have given my replacement pipe a thorough wrapping in high quality electrical tape (3M "33") and I am waiting for some plastic spiral wrap with which to protect the outside. Supercheap have some at a very good rate (6mm dia., $5 for 10m.), but the local SCA doesn't stock it.
Probably the best long-term solution is to drop the tank and replace all the plastic lines with flexible H.P. fuel line, by carefully removing the end fittings and re-using them. Then cable-tie them in place near the end to relieve any stress on the connections.
By the way, I have previously removed my tank, and the centre section of the towbar could not be removed. I removed the two bracing arms and the tank came out quite nicely.

My D2a is back together and running, the green fuel line is spiral-wrapped for its entire length, as are the other pipes where accessible. Random bits of water-pipe insulating foam are jammed in where they can discourage movement of the pipes and wiring harness.
I am feeling smug regarding my vibration prediction. When the motor is running there is a noticeable rapid pulsation in the green high pressure line adjacent to the tank. Combined with the fact that the fuel in the tanks of common rail vehicles gets stinking hot, I believe that this is the root cause of the chafing damage that often afflicts the high pressure line on TD5s (is it just on Discoverys or do Defenders suffer from this problem too?)
As a precaution I'm going to fit the old green ends to a length of high pressure fuel line and throw it in the back as a spare.
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I hope that posting my conclusions results in them being of some use to a fellow sufferer.
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Along the same tack, I wonder if DANNY2503 resolved his problem (see post #1 of this thread)

Originally Posted by Phil HH

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Along the same tack, I wonder if DANNY2503 resolved his problem (see post #1 of this thread)

Danny's issue sounds exactly like the same type my brother had with his D2 TD5 recently.
Problem seemed to sort itself out for some unknown reason, and I'm thinking his issue was more along the lines of failing ECU loom/wires.
His injector loom is all but brand new(no oil, no oil at the ECU plug, no oil in the ECU).

But this green HP line seems like an interesting point for us to inspect on his next time I catch him up.

He recently got his injector seal kit delivered too .. so that's another thing we're going to eliminate one day soon.

Phil, did yours do the cut out/engine dying routine?
Or did yours just have a fuel leak.
Brother's doesn't have any obvious leaking back there, other than the dribbles we caused when changing his fuel pump.
All I'm curious with his D2 now is any possible blockage in this green line for example due to compression of the line .. or something.

Arthur, my green line leak came on while using a car trailer to recover my son's Statesman. The leak sprayed out a considerable amount of fuel, and by the time I got the Statesman home (40km) the Disco, the trailer and the Statesman were well covered with diesel, and whenever I stopped a pool formed under the car. So, a fair sort of a leak, but the Disco (2003 TD5 manual) pulled strongly given its considerable load, and the motor showed no sign of fuel-distress.
I was glad to give it a heavy workout, as when I finish refurbishing our caravan I think I'll hardly notice it on behind. No surprise really, as my parents dragged that 'van all over the place behind a Datsun 200B.