leaking fuel need some advice
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Thread: leaking fuel need some advice

  1. #1
    FRESHMAN ROVER
    Join Date
    October 10th, 2010
    Location
    Burlington VT, Lenox MA, Edgertown MA
    Posts
    106

    leaking fuel need some advice

    Took the rover out on the beach yesterday and couldnt help but notice how much it smelled like fuel, then I noticed a fuel gauge fault message pop up on the display. Went under the RR and noticed fuel pooling up on top of the tank so it looks like new fuel lines. I've got close to 160k on the truck so ill probably do the pump while I'm at it. Ive found the pump cheap but does any one know where to find the lines for less than $200? or is that something you can have made at any garage? I'm situated on an island off an island right now so my options are pretty slim and I want all my parts before I even begin to drop my tank, and cutting the access hatch isnt an option I would consider due to the amount of salt water I expose this truck to.
    1996 P38 4.6 HSE Red
    1997 Disco Red
    2002 P38 4.6 HSE Green
    1991 KTM 250 EXC
    1982 Nacra 5.2

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  3. #2
    FRESHMAN ROVER
    Join Date
    October 10th, 2010
    Location
    Burlington VT, Lenox MA, Edgertown MA
    Posts
    106

    Re: leaking fuel need some advice

    $300 for the fuel lines no thank you! I guess I'll be making one myself does anyone have experience with AN lines and fittings? or know what threads are on the fuel pump and if they are the same as the female threads of the fuel filter.
    1996 P38 4.6 HSE Red
    1997 Disco Red
    2002 P38 4.6 HSE Green
    1991 KTM 250 EXC
    1982 Nacra 5.2

  4. #3
    FRESHMAN ROVER
    Join Date
    May 3rd, 2012
    Location
    Cradley Heath UK
    Posts
    95

    Re: leaking fuel need some advice

    When i had fuel on top of the fuel tank it was the pipework on the fuel pump itself that had failed, the fuel lines themselves were fine. From memory the fittings were compression type but whereas the fuel lines had an anti corrosion coating, the pipework that was part of the fuel pump assembly wasn't coated at all, my return feed rotted and literally fell off!

    leaking fuel need some advice-capture.png The pipes exiting the fuel pump assemble are really short, then onto flexes, didn't stop them rotting though!

  5. #4
    FRESHMAN ROVER
    Join Date
    October 10th, 2010
    Location
    Burlington VT, Lenox MA, Edgertown MA
    Posts
    106

    Re: leaking fuel need some advice

    Exiting the fuel pump should I use a 90 degree AN fitting attached to an m16 x 1.5 adapter like this
    leaking fuel need some advice-555-100022.jpg
    or the 45 degree like this
    leaking fuel need some advice-555-100012.jpg
    Or just stick with the straight this
    leaking fuel need some advice-555-100002.jpg
    and hope the SS flex line has enough bend. Im just worried the hose wont bend enough or that if I use an angled I wont clear the retaining ring.

    just to let you know the adapter I plan on using looks like this, I'm not sure this is what I need but the union to the fuel filter is m16 so I assume it should be the same at the pump.
    leaking fuel need some advice-361-9919efj.jpg

    BTW Im using this kind of hose in either 1/2 in or 5/8 which would be -8AN or -10AN
    leaking fuel need some advice-555100920.jpg
    1996 P38 4.6 HSE Red
    1997 Disco Red
    2002 P38 4.6 HSE Green
    1991 KTM 250 EXC
    1982 Nacra 5.2

  6. #5
    FRESHMAN ROVER
    Join Date
    May 3rd, 2012
    Location
    Cradley Heath UK
    Posts
    95

    Re: leaking fuel need some advice

    It's the straight fittings i'd be looking at. But honestly, it's no big deal to drop the tank. The filler hose is a bit of a fiddle but the main issue is how much fuel you have in the tank. Even a quarter tank makes it heavy. But if yours has failed the same as mine all your going to need is a new pump, the rest of the pipework will be fine.
    The standard setup uses fittings similar to the ones you show to connect the flex to the pump, but then the other end of the flex is crimped onto hard pipe. I presume you'll just use a pipe clip?
    I know you wanted to get everything together before you start but your making to many presumptions, drop the tank and see what you've got. I may be far easier than you think.

  7. #6
    FRESHMAN ROVER
    Join Date
    October 10th, 2010
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    Burlington VT, Lenox MA, Edgertown MA
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    Re: leaking fuel need some advice

    Arudge- I agree with you entirely about dropping the tank first but my problem is I am currently located on an island off an island and this truck is crucial to me getting anywhere so im trying to get this as many parts as I need before I take it out of service. I already bought the pump and it should be coming any day (in reality any week) now, but the fuel lines are definetly shot. Im almost out of petrol less than 50 mi range but still not on the light so I want to drive it about 20 more miles.

    If only somebody could tell me
    A.) are the pipes that exit the pump threaded, and if so male or female and what size and pitch. Every picture of a fuel pump I have found has the ends capped
    B.) what thread and pitch are on the other ends of the fuel lines, the ones closest to the fuel filter. Im pretty sure the hose entering the filter which would be the feed line is a M16 1.5 thread as an M16 2.0 fits but the threads bind after a quarter turn. The return line looks smaller to me but I may be wrong.
    C.) should I buy 3/8" ID hose or 1/2" ID hose.

    If anyone has a removed fuel pump would they be so kind as to let me know what size hardware to buy I need to order this stuff asap.
    Also for anyone who helps I can lend you my oversand beach permits for the the day If you make over to martha's vineyard this summer, that or just a nice cold one.
    1996 P38 4.6 HSE Red
    1997 Disco Red
    2002 P38 4.6 HSE Green
    1991 KTM 250 EXC
    1982 Nacra 5.2

  8. #7
    FRESHMAN ROVER
    Join Date
    October 10th, 2010
    Location
    Burlington VT, Lenox MA, Edgertown MA
    Posts
    106

    Re: leaking fuel need some advice

    Well the hose went today so I dropped the tank it wasnt very hard. I had my camera so I thought I would share some pictures. Dont flame me for my Improvised jack stands they are actually really solid.

    leaking fuel need some advice-484350_3336483371023_1731971019_n.jpg

    leaking fuel need some advice-525043_3336483011014_2128626810_n.jpg

    leaking fuel need some advice-575269_3336482571003_124915933_n.jpg

    leaking fuel need some advice-540656_3336482090991_1306667882_n.jpg
    1996 P38 4.6 HSE Red
    1997 Disco Red
    2002 P38 4.6 HSE Green
    1991 KTM 250 EXC
    1982 Nacra 5.2

  9. #8
    FRESHMAN ROVER
    Join Date
    October 10th, 2010
    Location
    Burlington VT, Lenox MA, Edgertown MA
    Posts
    106

    Re: leaking fuel need some advice

    just look at this fuel pump
    leaking fuel need some advice-600722_3336477890886_2085400656_n.jpg
    1996 P38 4.6 HSE Red
    1997 Disco Red
    2002 P38 4.6 HSE Green
    1991 KTM 250 EXC
    1982 Nacra 5.2

  10. #9
    FRESHMAN ROVER
    Join Date
    May 3rd, 2012
    Location
    Cradley Heath UK
    Posts
    95

    Re: leaking fuel need some advice

    Dear me, that looks even worse than mine did! What have you been up to?

  11. #10
    FRESHMAN ROVER
    Join Date
    October 10th, 2010
    Location
    Burlington VT, Lenox MA, Edgertown MA
    Posts
    106

    Re: leaking fuel need some advice

    Quote Originally Posted by arudge View Post
    Dear me, that looks even worse than mine did! What have you been up to?
    Well I took a gamble and ordered all the stainless lines and fittings which came to the grand total of $101. Thats less than half of what I was quoted by the parts suppliers here for oem. Im pretty sure I was right right on ordering 2 14mm -AN to metric adapters for the return and 2 16mm for the feed. When the the new pump and lines show up Ill be sure to take a few pictures of the setup, I just hope it works.
    1996 P38 4.6 HSE Red
    1997 Disco Red
    2002 P38 4.6 HSE Green
    1991 KTM 250 EXC
    1982 Nacra 5.2

  12. #11
    FRESHMAN ROVER
    Join Date
    October 10th, 2010
    Location
    Burlington VT, Lenox MA, Edgertown MA
    Posts
    106

    Re: leaking fuel need some advice

    Just a heads up to anyone interesed in making their own fuel lines here is a list of what you need

    1 x earls m16 x 1.5 to -6 AN oring type adapter (this connects fuel filter)
    1 x earls m14 x 1.5 to -6 AN oring type adapter (this connects the returen line union)
    2 x earls m12 x 1.5 to -6 AN adapter (for the fuel pump compression fittings)
    4 x jegs -6 AN straight hose ends
    about 6 feet of -6 AN fuel line (I got 10 to be safe)

    Ill post some picture when its all done, right now Im just waiting for the 2 12mm adapters.
    1996 P38 4.6 HSE Red
    1997 Disco Red
    2002 P38 4.6 HSE Green
    1991 KTM 250 EXC
    1982 Nacra 5.2

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