D2 Td5 fuel leak and fix

**LyleC** · 19th November 2022, 10:36 PM

Just posting some photos that I hope are useful for others, as it seems this is a fairly common problem with D2 Td5 over 250k km.
I found a fuel leak coming from somewhere at the top of the fuel tank right side other side of the chassis rail from the fuel filter.
Googling, I found the 'green' pipe is the likely culprit - this is the high pressure fuel line heading to the FPR on the engine.
Ordered a genuine green pipe in anticipation of the job this weekend. $120 -$140 from a few suppliers.
I decided to drop the tank to make sure I could check the whole area in case it wasn't just the green pipe.

So the leak was the green pipe, caused by the wring harness (for the fuel filter and rear right ABS sensor) running over it.
Also found wear but no leak on the white and black pipes where they cross each other.

I re-routed the wiring under the fuel lines, fitted the new green pipe, and wrapped the white and black pipes with self-fusing silicon tape at the point where they touch.
The new genuine green pipe came with an adhesive plastic patch which I wasn't sure how to fit but wrapped the pipe in the area where the old one wore out.
Not sure if you could do this job without dropping the tank.
And you need to keep the green retaining clip for the pipe to fuel pump connection as this doesn't come with the new pipe.

3 of the 4 Pipes laid out as they are on the car:
fuel pipes 1.jpg

The green pipe leak point
green leak.jpg

Old and new green pipes
fuel pipes 2.jpg

View of the pipes with tank removed
fuel pipes 3.jpg

Left over pipe protector with adhesive strip that came with the green pipe.
Anyone know how this should be put on?
pipe protector.jpg
Cheers

**Tins** · 20th November 2022, 09:20 AM

One for TGO?

**PhilipA** · 20th November 2022, 10:55 AM

Join the club. Happened to me on the GRR.

Had young switched on mechanic in Kununurra fix mine. I was sure glad, as the whole back of the car was covered with a concoction of dust and diesel. He placed cushioning foam tape the whole length across the cross member so hopefully will not happen again..

My failure was at the corner where the green line heads towards the front of the car on the driver's side and was due to a loose wiring loom presumably for a height sensor which my car doesn't have.

Funny thing was that the manifold was dated 2005 AFAIR ( car is 2002) so the failure was due to a sloppy mechanic doing the recall on the car for this same known problem.
Regards PhilipA

**Tins** · 20th November 2022, 11:33 AM

Originally Posted by PhilipA

so the failure was due to a sloppy mechanic doing the recall on the car for this same known problem.
Regards PhilipA

At a dealership? You shock me.

**LyleC** · 20th November 2022, 06:16 PM

Doing a general clean up today I picked up the old green pipe and noticed there was actually another area of wear.
Somewhere around where the first retainer clip is located. This clip on the chassis crossmember holds the four pipes after the 90 bend as they come away from fuel pump.

**Xtreme** · 20th November 2022, 06:50 PM

Happened to a friend's D2 on our Madigan Line trip in 2007.

Observant driver of following vehicle noticed fluid loss along track and rang the alarm bell so caught it before losing too much fuel. We didn't have a spare pipe so had to do a patch job with two part epoxy, flexible hose etc. Allowed to set overnight, proved satisfactory and got him all the way back to Sydney.

**d2dave** · 28th November 2022, 07:36 PM

This green pipe wear has been a well documented problem for years. Haven't checked mine yet.

I have a long range tank to go in, so will check it then and take steps to protect it.

A couple of years ago my sons started leaking from the same area as the OP's.

I told him it was common and I fixed it for him.

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