broncoduecer
Technical Excellence Contributor
If you're a proud owner of a 200/300 Tdi, you'll probably experience a leak at some point coming from the spill rail. This can be a couple things:
The tube is otherwise a 3.2mm hose. There are a few variants of the nipple on the banjo fittings out there. Some that we've seen are: straight, straight with single bulb/barb, & fully barbed.
The straight and straight with the single bulb/barb typically are found with a fabric insulated rubber hose. And the fully barbed is plastic hose that has been heated/pressed on. All types of hose can fail and are susceptible to age and heat. I had very low miles (<5k) and about 4 years on my new fabric insulated rubber set when it split.
There are a number of solutions to replacing the hose as suggested by members:
Installation of the "bling" kit from Blenddoor:
Seemingly good condition lines that leak:
New green Viton line kit (note I didn't install the line from the injector to the injection pump):
1 to 2 installed with clamps:
Some trimming to the acoustic cover because it was rubbing somewhat:
Finished product:
Now if anyone has a source for a nice green oval for my acoustic cover let me know! Then I can match the bling.
- Banjo bolts loose
- Copper washers for banjo bolts need replacing
- Spill rail tube has come off banjo fitting
- Spill rail tube has failed and is leaking
The tube is otherwise a 3.2mm hose. There are a few variants of the nipple on the banjo fittings out there. Some that we've seen are: straight, straight with single bulb/barb, & fully barbed.
The straight and straight with the single bulb/barb typically are found with a fabric insulated rubber hose. And the fully barbed is plastic hose that has been heated/pressed on. All types of hose can fail and are susceptible to age and heat. I had very low miles (<5k) and about 4 years on my new fabric insulated rubber set when it split.
There are a number of solutions to replacing the hose as suggested by members:
- OEM replacement part MJN100910
- Mercedes sprinter van return line from dealer
- Blue 5/16" ID Polyurethane Fuel Line https://www.jpcycles.com/product/44...2733&totalResult=1&isSearchByMotorcycle=False
- 3-4mm ID braided fuel hose
- The "bling" kit - green 3.2mm Viton hose, p/n MB20001-1 https://blenddoor.com/product/premium-land-rover/
- Using hose clamps
- Using a brake line tool to bubble flair the end
- Using a bead tool to add the bulb https://www.pegasusautoracing.com/productdetails.asp?RecID=31584
- Using your spare washers , part number ERR1304
- Filing down the washer slightly and reusing
- Heat up the copper washer till cherry red with a gas torch or even a gas stove top and let it air cool. Use a length of copper wire to hold them while heating and cooling.
- Worst case your injector face may be scarred and you need a new injector.
- 300Tdi Spill Rail - MJN100910
- Banjo bolt washer - ERR1304
- Banjo Bolt - ERR1200
- Banjo Bolt and washer set - STC3297
Installation of the "bling" kit from Blenddoor:
Seemingly good condition lines that leak:
New green Viton line kit (note I didn't install the line from the injector to the injection pump):
1 to 2 installed with clamps:
Some trimming to the acoustic cover because it was rubbing somewhat:
Finished product:
Now if anyone has a source for a nice green oval for my acoustic cover let me know! Then I can match the bling.