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Fuel lines air leak

Transit Mk3, 4 & 5(smiley front) Forum. All Transits 1986 - 2000

Fuel lines air leak

Postby Lyntransit » Tue Oct 28, 2025 12:40 pm

[Hi everyone I'm hoping someone can advice me concerning my 1994 transit 2.5 di. It's had a engine change from banana to the one with round air filter box. And its got the lucas cav pump fitted the dps one. The fuel filter is the one with a clamp with side know to clamp filter. Anyway it starts on the button but misfires on tick over I've done a full service and done the leak off mod but still the same i hve noticed if I spray brake cleaner over the two hard plastic pipes from fuel filter to the pump engine tone changes up also the two plastic pipes from lift pump to filter do the same but only when I spray them at the back of engine I can't seem to find pipes online. On the lift pump they clip on but not sure how to replace all the rigid ones. Any ideas. Cheers and thanks for reading.
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Re: Fuel lines air leak

Postby mk3_wrc » Sun Nov 02, 2025 11:48 pm

Tricky I think. Got very acquaintaned with the fuelling for our epic pumped van over the past week. You could fit normal 8mm ID injection hose on the lifter pump no bother but the rest are id6 type fittings but a bit longer and I couldnt find anything that would seal properly.
Id try ringing round wherever you can for replacement pipes.
2000 Transit 190 LWB 2.5di Turbo - Coachbuilt motorhome
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Re: Fuel lines air leak

Postby dumper » Mon Nov 03, 2025 7:07 am

I’ve had problems with the fuel filter in the past pushing the filter tight enough to seal in the end I removed it from the van supported the bottom of the filter so not to damage the drain plug and pushed the top down onto the filter and tighten the clamp to get a good seal
Back when you could walk round scrap yards I got a filter unit from a Land Rover and fitted that .
I did similar conversion on my mk3 a Lucas engine into a Bosch one and I used flexible fuel line from the connection out of the tank to the lift pump but not sure why I did
2025 MK 8 L3 H3 Motorsport campervan
Past camper vans
1974 mk1 v4 with 2.0 pinto fitted
1986 mk3 2.5 di swb
1990 190 lwb 2.5 di
1998 100 lwb 2.5 di
2006 350 jumbo 135 tdci
2015 MK 8 L4 H3 motorsport campervan
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Re: Fuel lines air leak

Postby Lyntransit » Sun Nov 09, 2025 9:12 pm

Update. So I've still got a misfire. Only slight but tried tappets. Fuel filter. Leak off mod. When I fitted new seals on the advance housing which had a leak it started after that. The only thing I don't know and trying to find out is the piston in the advance housing has two holes each side. One side has a perfect hole and the other side has a hole but cut out . I'm not sure which way it should be . Can anyone remember? The pipes from the lift pump then behind engine to filter one of them when I spray brake cleaner just behind rocker cover the engine revs up so I'm assuming air leak but camper starts on the button and revs fine and no smoke. If it was air leak it wouldn't start as it does . Stumped. Cheers
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Re: Fuel lines air leak

Postby dumper » Mon Nov 10, 2025 12:14 am

When my mk3 had the sealing problem it would start up from cold no problem but drive say 75 miles and stop at a shop on the way or at the destination and still hot it would be difficult to restart.
When you spray brake cleaner on the pipes I can’t see that making the engine rev up I’d expect it to be drawn into the air filter /bad seal on the inlet manifold/ breather pipe from oil filler cap to manifold pipe .
2025 MK 8 L3 H3 Motorsport campervan
Past camper vans
1974 mk1 v4 with 2.0 pinto fitted
1986 mk3 2.5 di swb
1990 190 lwb 2.5 di
1998 100 lwb 2.5 di
2006 350 jumbo 135 tdci
2015 MK 8 L4 H3 motorsport campervan
dumper
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Posts: 6358
Joined: Sun Jan 20, 2008 2:56 pm
Location: Lincolnshire

Re: Fuel lines air leak

Postby Mislaid » Mon Nov 10, 2025 5:57 pm

Can't remember orientation off top of head, but this might help....

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