200tdi spill rail leak - Defender Source
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  #1  
Old December 24th, 2012, 01:09 AM
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200tdi spill rail leak

Hello all, my 200tdi has developed a pretty significant fuel leak from the spill rail hoses. This started after the head and valves were completely redone. Engine runs better than ever but I see the fuel and the lines are wet. I have replaced them all with braided (what was on it to start) appropriately sized hose but still they leak. What's the next step?
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  #2  
Old December 24th, 2012, 01:31 AM
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Lr sells it as a single part number premade. I would go that route
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  #3  
Old December 24th, 2012, 09:51 AM
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And make sure the return line is clear to the tank.
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  #4  
Old December 24th, 2012, 10:50 AM
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I had a leak on the fuel rail on the 200tdi in the 110 and the hose was rubber.
I had a spare 200tdi and that had a black PVC pipe set up fitted as one piece.
I don't know if the rubber option was from Rover or was home made.
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  #5  
Old December 24th, 2012, 12:29 PM
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I just went through a similar problem. I replaced the hose with new German braided hose, it leaked almost immediately. It just did not grip onto the nipples very well. I replaced the fancy braided hose with standard rubber line from an auto parts store, worked perfectly.
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  #6  
Old December 24th, 2012, 12:31 PM
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I used a nitrile rubber tube I bought from McMaster Carr- works awesome. I have had problems with the replacement spill rails not being long enough between cylinders. Pisses me off when replacement parts dont even bolt on.
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  #7  
Old December 24th, 2012, 02:13 PM
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Thanks everyone. I'll try the new rubber hoses first and if that doesn't work then replace the whole she-bang
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  #8  
Old December 24th, 2012, 04:36 PM
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Quote:
And make sure the return line is clear to the tank.
I dunno about your 200 Tdi, but on mine the spill is returned to the inlet. No tank return.
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  #9  
Old December 24th, 2012, 10:02 PM
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Quote:
Originally Posted by 130Tdi View Post
I used a nitrile rubber tube I bought from McMaster Carr- works awesome. I have had problems with the replacement spill rails not being long enough between cylinders. Pisses me off when replacement parts dont even bolt on.
Any idea of the diameter or McMaster part number for this?
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  #10  
Old December 25th, 2012, 05:25 AM
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My original (when it was new) 200Tdi had stiff plastic pipe from the factory. they cracked eventually, so when I got a replacement for it, they'd changed the stiff plastic pipe to flexible rubber. never had a problem after that. the rigid pipes used to vibrate loose too.

The latest part # for the spill rail is ERR3652 and the little banjo bolts that bolt to the top of the injectors are ERR1200 (these come with 2 copper washers each)
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  #11  
Old December 25th, 2012, 07:24 PM
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I think the tubing is 4mm. Buy a hose that fits that.
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  #12  
Old September 27th, 2015, 11:12 AM
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Quote:
Originally Posted by o2batsea View Post
I dunno about your 200 Tdi, but on mine the spill is returned to the inlet. No tank return.
I'm having some air buildup in the fuel filter so I'm going through my fuel system again. Does it matter if the spill rail is plumbed back to the filter or should it go back to the tank?
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  #13  
Old September 27th, 2015, 11:17 AM
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If it goes back to the tank, air is purged out of the system easier and that is the stock setup.

On my spill rail, after switching to the new style, I replaced the hose between the injectors with 4mm (5/32") silicone hose. It is only a few bucks and should be more durable.
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  #14  
Old September 27th, 2015, 11:19 AM
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Quote:
Originally Posted by o2batsea View Post
I dunno about your 200 Tdi, but on mine the spill is returned to the inlet. No tank return.
That is weird. It should connect to the return line at the injection pump.
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  #15  
Old September 27th, 2015, 11:21 AM
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John do you have the oem fuel line routing handy? Or know where to track that down?
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  #16  
Old September 27th, 2015, 01:05 PM
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You can look through the part catalogs. There pictures of it all there. There are difference between models and tank locations.

Tank>sedimenter>lift pump>fuel filter>injection pump.

Spill rail connects to injection pump outlet with custom banjo fitting and the then run back to the tank. The return at the tank is a tube that goes to the bottom.

On my 90, the tubes run on top of the right hand chassis rail and are held by plastic clips.
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  #17  
Old September 27th, 2015, 01:53 PM
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Awesome thanks John
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  #18  
Old February 23rd, 2016, 10:59 AM
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Quote:
Originally Posted by Uncle Douglas View Post
I used a nitrile rubber tube I bought from McMaster Carr- works awesome. I have had problems with the replacement spill rails not being long enough between cylinders. Pisses me off when replacement parts dont even bolt on.
Quote:
Originally Posted by nathanwind View Post
Any idea of the diameter or McMaster part number for this?
Quote:
Originally Posted by o2batsea View Post
I think the tubing is 4mm. Buy a hose that fits that.

PN 54605K31 ??? 3/16" ID
Nitrile (Buna-N) Low-Pressure Fuel Hose
3/16" ID = 0.1875", 4mm OD = 0.1575"
too big ???
this is the closest i could find in 5 minutes for 4mm OD tubing
sold by the foot
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  #19  
Old February 23rd, 2016, 11:23 AM
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This is the kind of hose I use: http://www.amazon.com/High-Performan...ne+vacuum+hose

Very flexible and heat resistant.
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  #20  
Old February 23rd, 2016, 11:44 AM
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Quote:
Originally Posted by Red90 View Post
This is the kind of hose I use: http://www.amazon.com/High-Performan...ne+vacuum+hose

Very flexible and heat resistant.
Thanks John - I like your ERR3652/ERR1200 plan better as a long-term solution, but exploring the short term ones as well.
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