Technical Diesel spill pipe problem

[Dougie212]

Hi there

in The process of changing the diesel spill off pipe on our 2019 Fiat Ducato. The pieces across the injectors were pretty simple. The length that passes down under the engine however…… upon pulling that off the nipple has broken. Not only is is a nightmare to get to but I think the bracket and pipe fittings are one until.
I’ve managed to get a picture or two and put a yellow arrow where I pulled the spill pipe from. Could anyone help with how I would start replacing the part that the spill pipe fits onto please?
Thanks
Duncan

 

[jackwhoo]

Oh dear,
Those plastic fittings can break frustratingly easily.
You may have to find a tee piece and some sections of snug fitting fuel hose to bypass the broken plastic fitting.
J

 

[Dougie212]

Thankyou for your replay J..
I’ve ordered a replacement fuel pipe with this fitting on..

http://www.buycarparts.co.uk/gates/16173072

I’ve got underneath and it doesn’t seem to bad to reach, the only thing that is a bit of a bind is the banjo connector - whatever that goes onto is a bit awkward to get hold of.
All of that because I broke the bloomin spill pipe nipple.
Where would I bypass the spill pipe off to if I were to bypass the broken connector?
Thanks
Duncan

 

[Nickb500]

Thankyou for your replay J..
I’ve ordered a replacement fuel pipe with this fitting on..

http://www.buycarparts.co.uk/gates/16173072

I’ve got underneath and it doesn’t seem to bad to reach, the only thing that is a bit of a bind is the banjo connector - whatever that goes onto is a bit awkward to get hold of.
All of that because I broke the bloomin spill pipe nipple.
Where would I bypass the spill pipe off to if I were to bypass the broken connector?
Thanks
Duncan

Hi Dougie

Today I hit the same problem as you. The leak off pipe had sprung a leak where it was chafing on the engine block for some reason. Despite pulling carefully the plastic nipple snapped off so I am going to order the twin pipes with new nipple as mentioned by you.
These 2 pipes one with a banjo connector and one with a short rubber piece look rather inaccessible. Did you manage to complete yours?
I think it's going to involve removing the grille & radiator at least to gain access.
Any suggestions welcome!
Thanks, Nick

 

[sumpplug]

What i done to remove the banjo pipe i got 17 mil ring spanner and bent it in a vice, the other alternative is a socket on a long extension bar and work from top of engine, both options worked for me as i had to remove pipe more than once.

 

[sumpplug]

Just to add, the bent ring spanner was the most effective and also when you remove the banjo fitting there are 2 brass washer's 1top & 1 bottom of banjo bolt make sure they go back in place, i bent the ring spanner like an S shape with top & bottom streight.

 

[Nickb500]

Just for completeness I finished the job eventually and thought others may find this useful.

I raised the van about 6 inches using the standard jack on one side to give me some shoulder room/leverage (van wheel was still in contact with the ground). Removing the starter motor and solenoid plus cables (after disconnecting the battery) gave better access to the quick release clips and two bolts at the left hand side. To access the banjo connection and return pipe I removed the front grille and bonnet slam panel which allowed me to reach the banjo nut with a short 15mm ring spanner and jubilee clip with a short 8mm ratchet spanner. Fortunately that meant not touching the radiator or draining any water!

 

[Chris McGlinchey]

I have done this, twice. I ordered replacements from eBAY but I had to slightly modify them to make them fit correctly. I also upgraded the spill pipe to a thick rubber one. I took the opportunity to fit the pipe on the nipple before assembling the new parts. Hopefully it won't happen again.

Just a word of caution regarding the injector spill pipes. I bought a roll that was of very poor quality and I had 3 leaks within 6 weeks until I managed to source better ones.

 

[Communicator]

Just for completeness I finished the job eventually and thought others may find this useful.

I raised the van about 6 inches using the standard jack on one side to give me some shoulder room/leverage (van wheel was still in contact with the ground). Removing the starter motor and solenoid plus cables (after disconnecting the battery) gave better access to the quick release clips and two bolts at the left hand side. To access the banjo connection and return pipe I removed the front grille and bonnet slam panel which allowed me to reach the banjo nut with a short 15mm ring spanner and jubilee clip with a short 8mm ratchet spanner. Fortunately that meant not touching the radiator or draining any water!

Presuming that a "standard jack" is the usual scissor type for wheel changing only, this is not a safe procedure. The fact that the wheel was still touching the ground did not give any added safety. If the jack was to slip or fail in any way, the vehicle would still settle back onto the suspension, possibly to lower than normal height, with bump stops being the limiting factor.