How ToRange Rover

How to change the injector leak off pipes on a Range Rover DSE

Whilst hunting around the internet looking for a reason the Range Rover was slow to start in the mornings, one the possible problems suggested was the leak off pipes from the injectors.

These leak off pipes carry excess fuel from the injectors back to the injection pump. It is known that these pipes can go brittle and end up leaking air into the fuel system. Hence overnight, the air is drawn into the system, and it takes a period of time to start the car as the injection pump and fuel pump purge the fuel lines of air.

So I thought I would take a look. The tell tale sign is usually a little pool of diesel at the base of the injector where it screws into the head. Guess what I had on injector 1 – that’s right, a little pool of diesel, and upon closer inspection, injector 2 was a little wet at the base.

So it was time to change the leak off pipes, and this is how I did it.

Changing the leak off pipes on a diesel Range Rover

The new fuel pipe - 3.2mm internal diameterThis job isn’t very difficult, but can be a bit fiddly. Its also cheap to do, with 2 metres of rubber fuel hose costing less than £10.

The fuel hose required has an internal diameter (ID) of 3.2mm This is available from most motor factors around the country. You will also need the following tools to complete the job:

  • Flat head screw driver
  • Long nose pliers
  • Sharp stanley knife

The position of the jubilee clips on the air intake1: The first job is to remove the plastic air intake over the engine by undoing the 2 jubilee clips at either end. You can find the location of the jubilee clips in the photo on the right.

With the intake moved out of the way, you get clear access to the injectors.

2: Gentle pull the old fuel hose off of the first injector. If the old hose has gone hard, then you will have to carefully cut it off with a sharp knife, making sure you don’t score the metal pipe.

The position of the leak off pipesYou will notice the first injector (nearest the front of the car) also has a pipe that goes to the injection pump. I would recommend you replace this too.

3: Take the old piece of tube and measure it, and then cut the new hose to length. I cut the new hose slightly longer, which helps give better clearance around the injectors when you come to fit it.

Leak off pipe removed from injector 1 and 24: Its now time to fit the the first new hose. Where you have good access, you should just be able to push the tubing on with your hands. Where access is tighter, you will need to use the long nose pliers to help you push the new fuel hose over the injector pipes.

Just remember to take care, and work methodically. The last thing you want to do is use too much pressure and snap off the metal pipe end. This will result in a new injector, which is not cheap! I used a little bit of WD40 to help ease the hose onto the injector pipes.

The new fuel leak off pipes in place5: You will now need to repeat the above steps for the rest of the injectors. In my case, the Range Rover DSE uses the 6 cylinder BMW engine, so I replaced all the pipes on all 6 injectors.

Note: Number 6 injector (nearest bulkhead) has a blanked leak off pipe on one side. Inspect this for any leak or perishing, and replace if necessary.

6: When you have completed changing all the pipes, its a case of replacing the air intake across the engine. Replacement is the reverse of step 1!

Final steps: If like me, you had a small pool of diesel at the base of the injectors, I would recommend just mopping it up with some kitchen towel. This way you can visually see if your new pipes are doing their job and not leaking! Any subsequent pooling of diesel can then be investigated further!

Result: Did it solve my cold starting issue? Short answer – no, but it was a job worth doing as the pipes were leaking. So next jobs are to change the in-tank fuel pump and the change the glow plugs.

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