Disco 3 (LR3) Fuel leak after changing Camshaft & FIP belts

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johnlad said:
Hi
As Gary has said, on mine it plugs into the egr valve
Click to expand...
I have just had a look and there is already a grey connector plugged into the EGR cooler at the front end. The wiring length on the "Spare" mystery connector is approx 6" so it would have to mate with something close to the rear end of the battery box. I'll post a couple more pics shortly.

More woes, after thinking all was fixed, took the car out this morning and there is fuel p^&&ing out again. Have just taken the top cover off and the metal spill pipe connector is out of the rear L.H. injector (Looking in from the front). I double checked the clips were secure and the connectors pushed right in and they were 100% secure. A new clip was also fitted to this injector as that was the one initially where I found the spill pipe had come off the fitting and that prompted me to replace all spill pipes and fittings. Not a problem with the other bank.
This leak has only just started since changing the FIP belt etc. None of the injectors or fuel pipes apart from the LP feeds to the top rear of the engine were touched and there were no leaks before I started the job. The engine is running fine, sweet as a nut otherwise.
Just doing my head in now as it always seems to be the L.H. bank which is leaking.
 
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Irishrover said:
Took it with baited breath and it sailed through apart from an advisory for "Front Brake Pads showing signs of wear"-I thought that's what they did-wear !!
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That's a daft advisory isn't it. The wife's BMW convertible also had the same "brake pads showing signs of wear" advisory on the new MOT. The daft thing is, all the discs, pads and front calipers were new, just one week before the MOT.:confused:
 
Nodge68 said:
That's a daft advisory isn't it. The wife's BMW convertible also had the same "brake pads showing signs of wear" advisory on the new MOT. The daft thing is, all the discs, pads and front calipers were new, just one week before the MOT.:confused:
Click to expand...

Hi Nodge....I think the MOT places feel they have to put something down in the advisory section to make it appear that they have looked at the car !!
 
Just a thought....What if I have fitted the LP pipes the wrong way round at the top of the engine ??
On mine, there are two push in connectors, one has a blue release button and is attached to the Schrader type fuel bleed valve. The pipe I have fitted to that has a push on connector with a blue button that goes to the fuel cooler underneath the car.
The other push in connector close to the first on at the top of the engine has a white push in connector. The pipe fitted to that one, which also goes to the underside of the car, fits into a white push in connector located just in front of the fuel filter.
With both pipes disconnected in the engine bay and the ignition switched on, fuel flows from both pipes.Should this be the case, as I thought one was a feed from the LP intank pump and the other one a return or drain back to the tank.
 
IMG_0353.jpg

Here is the little bastid
 
Busy day today and just about ready to throw in the towel :confused:
After thinking it was sorted yesterday, took it for a short run an the back injector spill pipe fitting blew off on the way back. Gave the spring clip a squeeze to clamp the fitting, which appeared to be a fix then took it for another run. Did about 2 miles and smoke billowing from the engine...the middle spill pipe fitting had blown off.
Phoned a Diesel Fuel Injection specialist in Wrexham who said there could be a kinked or blocked return pipe somewhere. traced the spill pipe loom back to where it connects to the engine, just in front of the oil filter and found a kink in the pipe from the fuel temperature sensor to the push in connector to the engine. "Eureka", I thought. Removed the kinked pipe and replaced it with a short length of the spill pipe I had spare. Wire tied it onto the barbed ends and refitted it.
Bent the wire clip to grip the fitting on the centre injector and refitted it-checked the fitting for security, solid as a rock.
Took the car for another run and after 2 miles at the most.........smoke again and found the centre injector fitting had shot out again.
The Guy at Wrexham told me that the Peugeot Lion engine are beset with the same problem as I have.
There is no way I am going to throw much more time and money at the heap I appear to have inherited as I feel that any fix will be short lived.
 
UPDATE
Decided to spend another day on the Disco despite coming within a hairs breadth of selling it as a non runner.
As my other post, I started with trying to find the missing connector...and I did !!
Then moved on to the spill pipe blowing off problem. What had I done that was different to the original setup?
I discovered that the spill pipe from the "Y" piece on the fuel temp. sensor to the engine block was kinked and probably restricting the return flow. I replaced that section with a new piece of spill pipe which I had, yet when I took it for a test run afterwards the spill pipe fitting to the centre injector on the Left bank (Looking in from the front) blew out even after the restriction was resolved.
I then thought of anything else I had done with regard to the spill pipes and fittings to the injectors. The original spill pipes were a loose fit on the connectors, hence replacing all of them. The Right bank had not given any problems-only the Left.
I had asked a fuel injection specialist if the clips could be inserted any way round and was told "Yes". The Right bank injector clips were inserted from the front and the Left bank from the rear originally but due to the fact that it's very difficult to see what you are doing, I took the advice and put them in from the front. Today, I removed the"Box" from the area where the brake master cylinder is located, removed the Injector feed pipes from the fuel rail to give me more room and refitted the clips from the rear.
Started the engine and all was fine then decided to take her for a run with baited breath.
Gave her a good blasting along the A55 and I mean a good blast !! Good job there were no boys in blue around, the road was quiet and I exceeded the speed limit by quite a few MPH for 10 miles each way.
No plumes of smoke and ran as well as ever.
Hopefully that's sorted-I feel more confident that it's back to normal and had a last minute reprieve.
Thanks everyone, especially Gary for his unending support-would have thrown it in the bin otherwise !!
As always, fantastic LZ Guys to help out.
THANKS A MILLION !!!!
 
Irishrover said:
UPDATE
Decided to spend another day on the Disco despite coming within a hairs breadth of selling it as a non runner.
As my other post, I started with trying to find the missing connector...and I did !!
Then moved on to the spill pipe blowing off problem. What had I done that was different to the original setup?
I discovered that the spill pipe from the "Y" piece on the fuel temp. sensor to the engine block was kinked and probably restricting the return flow. I replaced that section with a new piece of spill pipe which I had, yet when I took it for a test run afterwards the spill pipe fitting to the centre injector on the Left bank (Looking in from the front) blew out even after the restriction was resolved.
I then thought of anything else I had done with regard to the spill pipes and fittings to the injectors. The original spill pipes were a loose fit on the connectors, hence replacing all of them. The Right bank had not given any problems-only the Left.
I had asked a fuel injection specialist if the clips could be inserted any way round and was told "Yes". The Right bank injector clips were inserted from the front and the Left bank from the rear originally but due to the fact that it's very difficult to see what you are doing, I took the advice and put them in from the front. Today, I removed the"Box" from the area where the brake master cylinder is located, removed the Injector feed pipes from the fuel rail to give me more room and refitted the clips from the rear.
Started the engine and all was fine then decided to take her for a run with baited breath.
Gave her a good blasting along the A55 and I mean a good blast !! Good job there were no boys in blue around, the road was quiet and I exceeded the speed limit by quite a few MPH for 10 miles each way.
No plumes of smoke and ran as well as ever.
Hopefully that's sorted-I feel more confident that it's back to normal and had a last minute reprieve.
Thanks everyone, especially Gary for his unending support-would have thrown it in the bin otherwise !!
As always, fantastic LZ Guys to help out.
THANKS A MILLION !!!!
Click to expand...

That’s great news mate and really pleased for u, always a pleasure to help where I can seeing there’s not many of us D3 owners think it nice being able to share info between us

Know what u mean about those clips where they can sometimes just not go into the groove enough so come back out

So are u now all done and dusted with everything

Really chuffed mate, put ur feet up and grab a few beers :D
 
Thanks Bud

TIP
When removing or refitting those fiddly clips, which have a habit of disappearing forever-buy or use a pair of locking forceps, the ones with bent ends (Available from most Angling shops).
Lock them on to the clip, gently prise the clip with a flat screwdriver until it is about a third of the way out and pull it out with the forceps-it should slide out easily. Refitting is the reversal of removal (As they say in the books)- when the clip is half way in, carefully push the clip almost home with the screwdriver, remove the forceps then locate fully with the screwdriver.

If the clip is sloppy coming out, give it a squeeze with a pair of pliers to tighten the "Bite" when it's inserted, but don't overdo it as it will be hard to insert.
 
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