Burst Fuel Pipe AGAIN

[cjc_td5]

Burst my second fuel pipe in 12 months on the weekend, the plastic pipe on top of the fuel tank both times.

Vehicle was serviced on Thursday which included a fuel filter change (though I dont think that had anything to do with it).

On the weekend on a 100km+ highway trip I noticed that power was down from normal. Hills that I would normally hold at 110km/h I was dropping to 100km/h and more throttle input was required. On one particularly long uphill grade the TD5 let out two huge "hicups" (similar to no ignition for say 1/3 of a second).

Then on Sunday arvo I noticed the dreaded diesel smell and looked underneath to see that familiar dripping diesel. There was a small split in the fuel line ontop of the tank near the fuel filter. Could not drive it home due to risk of the pipe splitting fully.

What was perplexing is that the fuel filter was too hot to touch. The car had only run for about 20km at slow speed at that time.

For you experts:
1) Can the fuel pump "over pressurise" the system (and continually spilt pipes?)
2) I cannot explain the power loss problem or know if it is related. I can only relate it back to a fuel pump pressure problem?
3) Could the hot fuel filter be caused by a fuel pump problem?
4) Are split fuel pipes a common problem?
5) How can I make sure this does not happen again?

The vehicle is under a extended vehicle warranty policy so that is covering towing to a good garage and will cover parts/labour. I was thinking of asking them to somehow test the pump to see if it is to spec?

D2 has done 80,000 km.

I await to be bombared by your combined knowledge.

[Graeme]

The excess returned fuel is hot as it gets recirculated in preferance to drawing cold fuel from the tank.

[Johnsy]

Check the recalls are all up to date... In particular the D169 regarding fuel hose chafing...View Recall*-*Land Rover Discovery Series II (Campaign No D169)

Johnsy

[cjc_td5]

The recall for the fuel pipe was allegedly done a couple of years ago by a LR dealer during a scheduled service. Then last year it burst. Now it has burst again!

My solution would be to split some heater hose down the side and wrap around the new fuel pipe so it will have NO CHANCE to chaf on anything! This would not help if the bursts are being caused by other issues though, hence my other questions...

[Scouse]

The recall for the fuel pipe was allegedly done a couple of years ago by a LR dealer during a scheduled service. Then last year it burst. Now it has burst again!

If the recall is not done properly, then the new pipe will continue to chafe & will end up leaking again.

We have one here today with the same issue. Luckily the recall wasn't done here originally.