Thread: Frustrating TD5 fuel leak

you need to have 1 lip of the seal inside the tank and the other outside is that the case?. you shouldn't need to use a hammer and chisel to tighten it although you can if gentle.

Hi discorevy, i did seat the new seal in the tank before fitting the pump, the locking ring went on easily, i just tapped it gently until i felt and heard it hit a stop... I see that the white inner part of the tank seal is available as a spare part, do these usually fail?

just did my 2001 TD5 Disco and initially re-used the original seal only to find that it leaked like a sieve. This was not evident at the time I did the seal due to the fuel tank level, it was only after I filled the tank to the brim that the fuel pump well filled up to the level of the tank and started overflowing, leaving a large puddle on the ground.
I drained some of the fuel into a jerry can to get the level down below the level of the seal, and, after ordering a new seal, installed it which in turn stopped the leak completely.

Make sure your tank is not full when you do the seal.

Make sure the seal is the right way up (flat section at top)

Fit seal to tank rim first and smear a little fuel around the inner edge of the seal to help the pump slide down more easily without binding.

When the pump bottoms out on the tank, the pump will depress a little further under spring tension ... make sure that the tang on the pumps housing lines up with the notch in the tank lip before screwing down the retainer ring.

Thanks rapserv, i did all that correctly, on the AULRO FB page someone told me that the clamp doesn't have a stop so it seems i have to tighten it up more, i was cautious about damaging it using a hammer....

I've seen some plans for a tool to tighten the clamp, so i may have to get one made as the prices for them are stupid!

TD5 Disco Fuel pump/sender unit - Land Rover Technical Archive - LR4x4 - The Land Rover Forum

This link is very helpful re pump removal and replacement in pictures.

Nick

Originally Posted by rpo83

Hi discorevy, i did seat the new seal in the tank before fitting the pump, the locking ring went on easily, i just tapped it gently until i felt and heard it hit a stop... I see that the white inner part of the tank seal is available as a spare part, do these usually fail?

Haven't seen one fail but that doesn't mean they can't.

I found when I changed mine. A 3rd hand is handy.
Someone holding the pump down while the other tightens. Way better than pushing a hammer down with your forehead while you try to tighten the lock ring.

Problem identified, the pump is weeping around one of the fuel lines, one of the yellow o-rings in the pump is a little worse for wear, it's not a high pressure line, it is a very slow weep, so it'll stay as it is over Christmas and then i'll order a new fuel pump and maybe lines....