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.
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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