FLK-004 Fitting Instructions — Defender 110 Td5 1998-2007
Bag-by-bag fitting instructions for your Pioneer 4x4 braided fuel line kit. Every line is supplied in a numbered bag — offer the kit up first, then work through the bags in order and check each run before you tighten anything.
| Model | Engine | Years | Fuel system | SKU |
|---|---|---|---|---|
| Defender 110 | Td5 | 1998-2007 | Diesel fuel lines | FLK-004 |
Colour coding matches the numbered bags below — each low-pressure line carries a coloured band so it goes back in the right place.
Before you start — fuel is flammable
Work in a well-ventilated area away from any source of ignition. Offer the new lines up to the vehicle and check them against the originals for length before removing anything. Drain the system, catch any spillage and keep fuel off the paintwork.
Fit using the new copper washers supplied, route without kinks or twists, and make sure every line sits in its original brackets and rubber bushes clear of the chassis and any moving parts. Bleed the system per the manufacturer's guidelines with fresh fuel, and check every connection for leaks before driving. If you are not confident, have the kit fitted by a competent garage.
Retain the coloured fuel-pump-housing clips
When you disconnect the lines at the fuel-pump housing in the top of the tank, keep the coloured retaining clips — they are part of the housing and are not supplied in the kit. Fit them onto the new male push connections, matching the colours to the lines in the schedule below.
Transfer the one-way valve and the air-bleed filter
Two small parts inside the OEM male quick-connects must be moved across to the new adapters. They are not supplied — reuse the originals or source new ones. The original O-rings work with the new adapters, and new copper washers are supplied for the four filter-housing adapters.
Red low-pressure line: the old male quick-connect contains a one-way valve (the 'bird beak'). Remove it and fit it inside the new adapter.
Td5 fuel filter housing — the non-return (bird beak) valve on the red low-pressure line. Not present on every model.
White air-bleed line: the old male quick-connect contains a small filter. Remove it and fit it inside the new adapter.
Download these instructions
A print-ready A4 PDF of this page — fitment, layout and the full bag schedule — to take out to the vehicle.
7 numbered bags
1 x Hose, 1 x Female quick connect for fuel cooler, 1 x adapter for fuel filterRed
From Fuel cooler → To Fuel filter
1 x Hose, 1 x Adapter for fuel regulator, 1 x adapter for fuel tankGreen
From Fuel regulator → To Fuel tank
1 x Hose, 1 x Adapter for fuel filter, 1 x Adapter for fuel tankWhite
From Fuel filter → To Fuel tank
1 x Hose, 1 x Adapter for fuel filter, 1 x Adapter for fuel tankBlue
From Fuel filter → To Fuel tank
1 x Hose, 1 x Adapter for fuel filter, 1 x Adapter for fuel tankBlack
From Fuel filter → To Fuel tank
1 x Female quick connect for fuel cooler, 1 x adapter for fuel regulator
From Fuel cooler → To Fuel regulator
Chassis clips and hose separators
Product page
Fuel Line Kit For Land Rover Defender 110 1998-2007 Td5
All kit instructions are listed on the fitting instructions page.
Stuck on something?
If anything does not match what is in front of you, stop and ask before fitting.
Email pioneer4x4@outlook.com · Tel 01404 643149