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CJs110



Member Since: 06 Sep 2023
Location: Windsor
Posts: 22

Canada 2003 Defender 110 Td5 SW Zambezi Silver
15P Fuel Pressure Regulator Pipe (Into Head)
Hi All,

Had a fuel leak which I confirmed is a pinhole in the rubber hose with metal ends that runs from the Fuel Pressure Regulator into the head (3 pipe version, 15P engine)



Click image to enlarge



I thought it would be a straight forward replacement (had to order a whole FPR unit, couldn't find the pipe separate) but I can't figure out how to approach removing the connection towards the front of the head, there seems to be no clearance to get the pipe off (highlighted in red)



Click image to enlarge



Has anyone replaced this pipe before? If so how? Do I have to remove the entire intake assembly Big Cry

It's currently -8c out so I was hoping it would be straightforward and could just do on the driveway but I guess I gotta get into the garage Laughing
Post #1058513 24th Jan 2025 10:39pm
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CJs110



Member Since: 06 Sep 2023
Location: Windsor
Posts: 22

Canada 2003 Defender 110 Td5 SW Zambezi Silver
Update: Definetely need to remove the Intake/Inlet manifold
Ok probably should have done my research before posting, looking around the internet looks like no tool will really reach that

So off the inlet manifold must come Crying or Very sad

Just ordered a gasket, once that comes in guess I'll get cracking
Post #1058514 24th Jan 2025 11:07pm
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landy andy



Member Since: 15 Feb 2009
Location: Ware, Herts
Posts: 5815

2006 Defender 110 Td5 USW Zermatt Silver
I swapped mine out last year. Just used an open end of a spanner only get the smallest part of a turn, but enough that it worked without taking anything off.
Post #1058516 24th Jan 2025 11:34pm
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CJs110



Member Since: 06 Sep 2023
Location: Windsor
Posts: 22

Canada 2003 Defender 110 Td5 SW Zambezi Silver
I've got atleast till next weekend before that gasket comes in, so I'll try and get it in the garage and try again with a spanner - maybe from underneath? When I just tried earlier I kept contacting the manifold runners or the head casting itself.
Post #1058517 24th Jan 2025 11:39pm
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landy andy



Member Since: 15 Feb 2009
Location: Ware, Herts
Posts: 5815

2006 Defender 110 Td5 USW Zermatt Silver
I had swapped my FPR about 18 months/2 years before and had not used the new along the engine pipe. So when mine started to leak at the joint of hose to solid pipe I had it in stock. I managed from above just with open ended spanner. Maybe try a different spanner as head angle maybe different on it.


I, like you, thought I was in for a big job, but ended up being a breeze of a job.
Post #1058521 25th Jan 2025 12:22am
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Ashbyandy



Member Since: 17 Dec 2015
Location: Leicestershire
Posts: 224

England 2015 Defender 110 Puma 2.2 Adventure Phoenix Orange
A mechanic at my local indi, used a grinder and cut an old spanner down on each side, making it very narrow, which then made it easier to get to. You could just buy a cheap open ended spanner, and try it πŸ‘. Hope you can manage it without removing the manifold, saves the risk of breaking any studs, which would be a pain to fix,

Ashby Andy
Post #1058531 25th Jan 2025 9:54am
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CJs110



Member Since: 06 Sep 2023
Location: Windsor
Posts: 22

Canada 2003 Defender 110 Td5 SW Zambezi Silver
Found a spare spanner and used a grinder to thin it out, but still wasn't able to quite get it. I figured I need to remove the alternator support bracket and in undoing the bottom bolt I may have made my situation worse as now I see wetness around the Alternator Oil Feed (likely when loosening the bottom bracket bolt I put too much pressure?) Rolling Eyes



Click image to enlarge



Might have to order YKL100120 now too.....


If I have some more time I may modify the spanner more to try and get in, but it feels like the closest inlet manifold stud/nut prevents me from really reaching the fuel pipe. But at this point inlet gasket ordered so I'm preparing myself to go down that avenue.
Post #1058591 25th Jan 2025 7:09pm
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Newlandy



Member Since: 01 Apr 2024
Location: Gauteng
Posts: 9

South Africa 2003 Defender 110 2.5 TD CSW Arles Blue
While you're at it, replace the oem pipe with a quick connect fitting on each end, then in future you just replace the pipe but leave the tricky steel pipe end in place.
Post #1059651 6th Feb 2025 7:20am
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bankz5152



Member Since: 02 Feb 2017
Location: South London/North Kent
Posts: 2194

2004 Defender 110 Td5 DCPU Epsom Green
You can access it if you drop the alternator off its bracket and swing it down. Helps to use a fuel rail tool.

Basically a 14mm socket on an extension with a slot in it to get round the fuel line. Instagram @defender_ventures
Empire Tuning - Agent
Post #1059692 6th Feb 2025 3:20pm
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CJs110



Member Since: 06 Sep 2023
Location: Windsor
Posts: 22

Canada 2003 Defender 110 Td5 SW Zambezi Silver
Just an update
I ended up ordering a inlet manifold gasket and a 14MM fuel rail socket - both showed up around the same time lol.

I was going to drop the alternator but the oil fitting line to it (which I previously mentioned might leak) worried me because the end into the head seemed to want to round. So I went with the remove inlet manifold route - which I thought would give me a good chance to clean the intake out.

Drop fuel cooler, remove inlet hose, glow plug wires, dipstick holdown, MAP and it was pretty easy. Enough access to get the manifold bolts off no problem. Once removed I ended up swapping the whole FPR assembly (hose included). For the intake itself turns out it was extremely clean!! Nothing to really clean out (likely because EGR deleted)....

Anyways reverse assembly steps, test drive, and the TD5 is back up and running - just in time too the weather may warm up soon.
Post #1061550 27th Feb 2025 7:29pm
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4RF RDS



Member Since: 19 Jul 2015
Location: Ottawa
Posts: 962

Canada 2000 Defender 110 Td5 XS CSW Epsom Green
Warm up??!? Its getting colder and we’re getting 15 cms of snow πŸ˜† 2010 Range Rover MkIII Autobiography Super Charged (Idris)
2003 Range Rover Mk III (Desmond FitzWilliam)
2000 Defender 110 CSW TD5 (CTX)
1992 Range Rover Classic (Lizzy)
1972 Series III 300 Tdi (Stanwood)
1967 MGB GT

Every normal man must be tempted at times to spit on his hands, hoist the black flag, and begin to slit throats.
H. L. Mencken (1880 - 1956)
Post #1061607 28th Feb 2025 4:30pm
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CJs110



Member Since: 06 Sep 2023
Location: Windsor
Posts: 22

Canada 2003 Defender 110 Td5 SW Zambezi Silver
Might be an Ottawa thing lol

Windsor was +8c Friday. Bit cold Sat/Sun, but today and the rest of the week is +ve.
Post #1061894 3rd Mar 2025 8:41pm
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