Nuisance Leak - Spill Rail 200tdi

[Tbaumer]

Repeat spill rail leaks at the injectors, from the banjo bolts coming loose. Tightened to the recommended 9nm specification in the manual & overtightened when that didn't hold long. The hard plastic lines transfer vibration to the banjo bolts, so I replaced with flexible Viton tubing (1/8" Fluoroelastomer Hose• 100% Biodiesel Compatible • Max 400°F, Max 100 PSI at 70°F• 1/8" ID, 0.23" OD, 1.33mm Wall) between the injectors, new banjo bolts & crush washers. The previous banjo bolts had stacked copper crush washers (two) between the banjo bolt & injector (& one on the bolt head side). I only see one crush washer on each side of the banjo bolt in the manual, so that's how I installed the new banjo bolts & crush washers. No fresh leaks after a test drive. Hope this problem is solved.
Could the previous stacked washers have caused the frequent loosening?

 

[O2batsea]

absolutely

 

[Napalm00]

I actually just bought a spill rail kit as well... The washers that it came with are aluminum and I'll be swamping them out for a copper ones. The aluminum ones always seem to leak for me?

 

[Tbaumer]

I thought of just ordering a kit, but read that the tubing can be a bit short & require some stretching to fit. Does the new spill rail kit come with more flexible lines than the original tubing?

 

[Napalm00]

Na it sucks , I just cut it off and use polyurethane fuel hose

 

[Napalm00]

Here's mine on the new engine

 

[AdamSanta85]

I used the black poly tubes spill rail on my truck. It was a pain to fit but once I got it lined up and fitted, it never gave me any trouble.

 

[MountainD]

View attachment 16188Here's mine on the new engine

Such a clean engine. Question on the fuel rail--I know that is a 200tdi block with a 300tdi head---but can I use those double barbed banjo bolts on my 200TDI injectors to clean up my fuel rail or are they a different size (if you know)?

 

[Napalm00]

Banjo bolts are the same size You can use them. Early 200 also had double barbed connections, just a different shape

 

[Tbaumer]

Yeah, all you guys with shiny engines...
I like those double barbed injector banjos as well. I don't think it would be quite as tidy on a 200tdi head, as all the injectors sit at an angle, so it looks like the banjo bolts would have to be rotated with one barb up.

 

[Napalm00]

I'll take a pic of my other engine later so you can see what the early ones look like.

 

[Napalm00]

Here is the old style , under/over 200tdi. It's similar to the 300 but the barbs are curved. I prefer the 300 style now that I've had all of them