Vehicles

disco - Fixing Leaking Fuel Line

The Disco was leaking fuel. At first I could smell fuel but not see it. Eventually it got so bad that I could see fuel dripping onto the ground. This was a blessing and a curse. I could now finally see where it was dripping from, but it was dripping right onto the exhauast so I couldn't drive the vehicle anymore without risking exploding into tiny pieces.

The fuel lines on this vehicle are weird (to me). They are not metal or rubber, they are plastic. Apparently this type of line is rated for diesel too, which makes sense why they would just use the same lines for the gas engines.

The line was leaking right behind the engine, on top of the transmission. The plastic line transitions to a flexible rubber section for the last 6 inches. One of the joints connecting the plastic line to the rubber line was leaking. The plastic line actually has a metal liner on the end and a ring allowing a rubber hose to be directly clamped around the plastic line.

Getting to that line proved to be a pain in the butt. The inake manifold needs to come off, the ignition coil needs to come out, and some exahust emissions stuff needs to be removed. It is annoying but was done in about 5 hours of me learning as I went.

By the way, this plastic line and the connectors is sold as a single part, and that part is no longer sold by Land Rover. As a result, I just bought some rubber fuel injection hose that was just barely smaller than what was on there originally. I also bought some better hose clamps. It was very difficult to get the rubber line on given the slightly smaller inner diameter but I am happy to report that after a couple months of driving no leaks have reappeared.

Pictures

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before the teardown
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the line leaks from behind the engine. Fuel runs down the fuel line and drips onto the exhaust
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ugh, the line is very hard to get to. And this is not even where it is actually leaking
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I separated the solenoid from the exhaust line because I couldn't get the exhaust lines off the blk
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Just keep removing the next thing in your way until the upper intake manifold is out
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oh, you're not done yet. Now the ignition coil and wires are in the way
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yeah, and that thing needs to come out. Some sort of air line, no coolant in it
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jeez, this line is really buried
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Finally we can see the line. It was leaking at the top hose clamp
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the quick disconnect that connects the rubber line to the metal fuel rail
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was a pain to get off thanks to some dirt in the fitting
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metal fuel rail connector. Rubber line goes on quick disconnect, which attaches to metal fitting
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now in back you can see the metal reinforced plastic fuel line
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This is what the end of that plastic fuel line looks like
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The fuel return line with original rubber and clamps.
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Old line was Gate 4219BG. Its nice hose and clearly newer. Not sure why it was leaking
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I ended up installing 1/4" fuel injection hose. The I.D. was smaller which lead to a great seal
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but the smaller I.D. made it a pain to get over the fittings. I coudln't get them fully seated
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even without fully seating them there are no leaks and that line is never coming off without a knife
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new line installed
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new upper intake manifold gasket
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all back together, no leaks

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