 | Home > Technical > Replacing fuel hose (TD5) / inspection hatch. |
 
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| TexasRover Member Since: 24 Nov 2022 Location: Paris Posts: 798   
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Yes correct, disconnect at pump pull back, feed back in and reconnect.
Don't mix the hoses The fuel filter connection can be sources of air entry either because they have corroded and possibly if they are disturbed. Dont bend the plastic lines, the could be brittle by now and crack There looks to be an air/garden hose in your bundle so I expect it has been messed with. You can either keep on messing or consider buying or getting a new hose set from engine to pump with the filter in the middle. |
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27th Oct 2023 12:17pm |
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| Firebird Member Since: 27 Oct 2023 Location: Helsinki Posts: 10  
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 Click image to enlarge I’m about to take the faulty file line out. Can someone please confirm that the one indicated with a green sticker (fuel pump end) is the one that goes onto the filter as per my arrow at the other end. As this is my first time attempting this, can I ask what I should expect? I.e Will a large volume of diesel spill out? Also I haven’t got a pair of fuel line clip pliers. Are they really needed? Any tips here for getting the line out at both ends? I guess removing the back right wheel will also help with access etc. Many thanks for your knowledge and help. Click image to enlarge |
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1st Nov 2023 10:09pm |
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| NickMc Member Since: 01 Oct 2014 Location: Norn Iron Posts: 1571  
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Clean the connections with some brake cleaner or wd40 and blow with the air gun or hoover all the debris away first this will help them come out without breaking. A pair of 45 degree needle nose pliers is the best tool I’ve found to squeeze the tangs, take the ones of next to it as it makes removal easier for access to the clips. Some diesel will spill but not a lot. Take the keys out so no one turns the pump on by accident.
You will probably have to take the pair off at the filter to get them out. Again make sure you clean the locking square parts out, it make removal and damage less likely. I have a pair of pliers like these for squeezing the square button clips off makes it so much easier https://www.amazon.co.uk/Kraftmann-413-Spa...&psc=1 |
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2nd Nov 2023 12:13am |
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| DSC-off Member Since: 16 Oct 2014 Location: North East Posts: 1352  
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The green marked hose in your photo is the supply from the pump to the fuel pressure regulator.
The black hose in the diagram below is the low pressure return from filter to pump. 
Click image to enlarge |
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2nd Nov 2023 12:22am |
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| Firebird Member Since: 27 Oct 2023 Location: Helsinki Posts: 10
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That diagram is just what I needed. Many thanks for your help.
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2nd Nov 2023 10:51am |
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| Firebird Member Since: 27 Oct 2023 Location: Helsinki Posts: 10
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Is there a way to fix a WJP107930 line that has a hole in it? Being in Finland, may take some time to get a replacement line sent over from the UK. Maybe take it to hydraulic hose place for repair or any other ideas? Many thanks.
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2nd Nov 2023 12:11pm |
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| DSC-off Member Since: 16 Oct 2014 Location: North East Posts: 1352
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Hi, I did the same job recently and just replaced the hose with standard high pressure fuel hose, of the correct inside diameter. Hose clips (Jubilee clips) were used to secure it to the original plastic fittings.
The hose was from a local car parts supply shop for only a few £. |
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2nd Nov 2023 12:50pm |
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| TexasRover Member Since: 24 Nov 2022 Location: Paris Posts: 798
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There are a whole bunch of fuel hose solutions on the market probably better and cheaper than buying the performed LR hoses, but you have to be a little creative. You can buy the same nylon hose and the fittings and a tool to insert the fittings on the hose (press fit) or there are press fittings as well.
Rubber hose with hose clamps could be used for short term, but is not a very reliable long term solution |
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2nd Nov 2023 1:22pm |
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| MadTom Member Since: 10 Sep 2013 Location: Olomouc Posts: 578  
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What is bad on proper rubber hoses designed for fuel and with enough pressure rating? They just need some clamps to stop vibrating. "Drobek" = The Small One - Discovery 2, "Blufínek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo
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2nd Nov 2023 8:51pm |
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| TexasRover Member Since: 24 Nov 2022 Location: Paris Posts: 798
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Because with time they tend to crack/ooze. I am sure there is probably some high quality rubber out there that does not, but I have fitted some rubber hose purchased as fuel hose that did not live particularly long before needing replacement.
I have has better luck with PTFE style hose, but obviously it's your choice. |
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3rd Nov 2023 4:59am |
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| Screbble Member Since: 26 Apr 2015 Location: Lancashire Posts: 2052 
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I don’t suppose…
Anyone has the dimensions for the ‘retrofitted inspection hatch’ on a 90 (TD5). I know it isn’t the most difficult measurement to make but I’d rather learn from others’ mistakes… |
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4th Nov 2023 10:25am |
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| jim4244 Member Since: 13 Apr 2014 Location: Bedfordshire Posts: 641  
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Scrabble
I cut a circular hatch in the floor of a TD5 I owned a few years ago and then installed a watertight marine/boat hatch. This post has the measurements, photos and YouTube link https://www.defender2.net/forum/post823648.html#823648 Jim |
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4th Nov 2023 12:56pm |
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| Screbble Member Since: 26 Apr 2015 Location: Lancashire Posts: 2052
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You absolute star Jim!
Thank you very much 👍 |
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4th Nov 2023 2:10pm |
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| Screbble Member Since: 26 Apr 2015 Location: Lancashire Posts: 2052
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Just ordered my 200mm marine hatch 👍
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4th Nov 2023 6:07pm |
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