200tdi Fuel system refresh and Stainless hoses

Napalm00

Technical Excellence Contributor
After the few engine out services I've done this year I was totally sick of the stock nylon/plastic fuel tubing. It kinks, leaks, the land rover fittings are impossible to find,ect ect. It sucks

So I did a ton of research on the fitting types in the 200tdi. The fuel pump being the most important.

200tdi fuel pump had 1/2x20 tube nut and olive connection using 8mm tube
You can use a -06 an to 1/2x20 inverted flare adapter and a copper washer to seal. The inverted flare is the correct thread but the wrong seal type, the copper washer does the sealing.

I then searched for the adapter above with a large flat space for thr washer to seal against. Most didn't have it except for the jegs branded one.

Also bought some 90 degree hose ends, straight hose end and a 5/16(8mm) tubing hard line to -06 an adapter.

Was my first time making hoses, and cutting the braided line is challenging, I found d that wrapping with aluminum ducting tape and cutting with a angle grinder and thin disc worked best.


Im getting the tank lines done after the tank is replaced. They work great with no leaks!

Via Jegs:

http://www.jegs.com/i/Vibrant-Performance/231/16455/10002/-1 (8mm steel tubing to an hose adapter)
http://www.jegs.com/i/JEGS-Performance-Products/555/110021/10002/-1(90 degree an hose end)
http://www.jegs.com/i/JEGS-Performance-Products/555/110001/10002/-1(straight hose end)
http://www.jegs.com/i/Vibrant-Performance/231/10222/10002/-1(an to 3/8 NPT adapter, only if you are using FM100 fuel manger or something similar)
http://www.jegs.com/i/JEGS-Performance-Products/555/110540/10002/-1(1/2x20 to an adapter for fuel pump)
http://www.jegs.com/i/JEGS-Performance-Products/555/100910/10002/-1(-6an fuel hose 3 foot length)

Other things needed/helpful:

1/2 copper crush washers
dremel or grinder with thin cutting disc
Flare nut or line wrenches
aluminum vise jaws (a must)


If you are using the stock fuel filter you may need different adapters that what is listed, ditch that garbage anyway!

I added a racor ps120 prefilter instead of a sedimenter. It is mounted approximately where the TD5 style fuel filter would be on a plate mount.

I may replace the input line fitting to a 45 degree to release some stress on the line. But for now it seems fine.
The fuel pump needed a 180 degree hose end on the input side, im sure a different brand with a larger bend radius would fit better, but this one matches and it was comparatively cheap

A new Cat branded 5 micron element tops it all off.


I can provide more part numbers if needed. The only new thing on here is the Racor PS120-02 prefilter it cleans from 200-260 micron and has 3/8 npt ports. I trust this 100x more than a sedimenter is also about $65 shipped.
 

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Dan kemper

Founding Member
Callsign: KK6ECF
Nice work again. I invested in the stainless hose cutter and makes perfect cuts. Worth the expense if you are making more than a few lines. Good job
 

Tomaco1

Well-known member
Just a heads up, where the hoses touch the body it ate through the aluminum on my body.
 

RDavisinVA

Technical Excellence Contributor
After the few engine out services I've done this year I was totally sick of the stock nylon/plastic fuel tubing. It kinks, leaks, the land rover fittings are impossible to find,ect ect. It sucks

So I did a ton of research on the fitting types in the 200tdi. The fuel pump being the most important...
Nice Job and write up.
Love the picture of the hand holding a fist full of bull shit nylon line with rubber pushed onto 1 or 2 of the nylon lines.

The only thing I would have added would have been a 12V fuel pump just after the sedimenter so the system is self priming, but you have done a really good job on your fuel system.
 

Napalm00

Technical Excellence Contributor
Nice Job and write up.
Love the picture of the hand holding a fist full of bull shit nylon line with rubber pushed onto 1 or 2 of the nylon lines.

The only thing I would have added would have been a 12V fuel pump just after the sedimenter so the system is self priming, but you have done a really good job on your fuel system.
Nice work Matt.

Electric pump that thing!
Thanks guys . I actually have a primer pump built into the fm100 fuel manager. On the top of the filter is a plunger you push down. It primes to the filter head and past the filter if you keep pushing. Takes about 5min of plunging to fully prime a dry system. No need to even touch the lift pump!
 

rovercolorado

Well-known member
Thanks guys . I actually have a primer pump built into the fm100 fuel manager. On the top of the filter is a plunger you push down. It primes to the filter head and past the filter if you keep pushing. Takes about 5min of plunging to fully prime a dry system. No need to even touch the lift pump!
That's a good idea. Great write up!
 

RBBailey

NAS-ROW Addict
Callsign: KF7KFZ
So the SS braided is merely inserted to the hose end fittings, and when tightened down they clamp enough for no leaks? Need to look for a video on installing these fittings.
 

Napalm00

Technical Excellence Contributor
No, it's a special hard tube to braided hose male fitting. It's listed above

One side is compression one is flare an
 

Napalm00

Technical Excellence Contributor
There are adapters yes, each connection requires an adapter and a hose end. It's gets expensive!

I don't know the fittings on the rover fuel filter you have. If you have some pics I can tell you. Iirc the top is a banjo bolt and the side is 1/2x20 but you would have to confirm

If yours is leaking might as well just replace the whole thing with one of Robert's or the stanadyne fm100 fuel manager I used
 

RBBailey

NAS-ROW Addict
Callsign: KF7KFZ
Na, it is fine. I'm just thinking of doing the braided lines for in the engine bay where the corners and heat are a factor.

I like the look, and it seems like it will last forever.
 

Napalm00

Technical Excellence Contributor
They do look really really good, and if just doing engine side it will make pulling and replacing the engine much easier
 

RBBailey

NAS-ROW Addict
Callsign: KF7KFZ
What did you use to actually get back to the fuel tank? Braided all the way? I'm thinking the three foot length wouldn't make it that far!
 
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