200Tdi injection fuel return line banjo bolt - Defender Source
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  #1  
Old February 5th, 2013, 02:34 AM
Apocalypse Vehicle
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200Tdi injection fuel return line banjo bolt

Anyone know the part # for the banjo on the back of a 200tdi fuel injection pump? I put a 200tdi in my 1961 series and the engine is missing this banjo. I have the fuel feed banjo on the top but I need the return fuel banjo with the small pin hole. I can't find a part number anywhere for it. I can find the fuel feed banjo part #STC3597. This is the only thing keeping me from starting this thing up. Here is a schematic of the injection pump. #11 is the fuel feed banjo but no info on the return line banjo.


http://www.allbrit.de/UNI.cfm?PAGE=786569&SPRACHE=EN


Thanks

Evian
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  #2  
Old February 5th, 2013, 07:35 AM
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Neill Thornton
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It looks like you already have the same info as MicroCat and the old school parts book.

There are two banjo bolts listed on the parts catalog:

ERR866 - BOLT, BANJO
ERR1125 - BOLT, BANJO, FUEL INLET

Not sure how STC3597 plays into it... since you need 3 total (fuel from tank, injector return, spill rail back to tank) I would imagine it's one of the 3 here.
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  #3  
Old February 5th, 2013, 09:47 AM
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STC3597 has a very small hole in it, but it says it for a 300TDI,

I stand corrected it is also listed for a 200tdi
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  #4  
Old February 5th, 2013, 08:31 PM
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Yeah I was a little confused because the picture shows it with a small hole but also shows it going where the fees banjo goes. err866 looks to have a large hole but is located in the back. Might just have to order both and see what happens. It may be the same as a Mercedes om617 engine. They both have Bosch fuel injections. I'm going to stop by a local business that rebuilds Bosch injections, maybe they have one laying around. If not ill have to order overseas.
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Old February 5th, 2013, 08:49 PM
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We can check!

Quote:
Originally Posted by Apocalypse Vehicle View Post
Yeah I was a little confused because the picture shows it with a small hole but also shows it going where the fees banjo goes. err866 looks to have a large hole but is located in the back. Might just have to order both and see what happens. It may be the same as a Mercedes om617 engine. They both have Bosch fuel injections. I'm going to stop by a local business that rebuilds Bosch injections, maybe they have one laying around. If not ill have to order overseas.
There is a LR 200TDI right next to a Mercedes OM617 in our shop.
What do you want me to check exactly??
Fuel return banjo bolts among the 2 engines?
The size of the hole is only for the pressure bleed out of the pump to prevent air entering and causing fuel starvation at or before start up.
We can pull both banjo bolts and compare with pictures if that will help you...
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Old August 11th, 2013, 08:15 PM
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are these Banjo bolts available anywhere pre drilled for safety wire? I ate up three titanium bits today trying to get a safety wire hole in one. messed up my safety wire drilling guide a bit too.

Alternatively is there any other way to get the return lines safetied down other than lock tight?
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Old August 11th, 2013, 08:50 PM
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Lock tite is a good plan. They do come loose, and make a mess with diesel leakage.
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Old August 11th, 2013, 09:29 PM
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loctite has already failed. looking for something else.
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Old August 20th, 2013, 11:13 AM
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Just need a set of safety wire pliers.
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