300 Tdi single fuel line - Defender Source
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  #1  
Old April 2nd, 2011, 09:43 AM
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Michael White
110 Tdi
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300 Tdi single fuel line

Hi all,

I'm replacing the fuel tank on my 110 300 Tdi (originally a MOD LHD 2.5 N/A diesel), and was sent a fuel tank without a hole on the top, even though I ordered one with the hole on top to match the leaking one. While grumbling about it and taking the return line off the top, I notice the return line is bone dry. Tracing the return line back to the engine compartment, I see the return line is plugged off.

I did not do this conversion, but I was told that my 300 Tdi was one of the last ones that were made (2002-2003?). At some point late in the 300 Tdi line, did they switch to a single fuel line setup? Or is this just a bad install? The engine has about 44,000 miles, and seems to run fine.

Thanks.

------ Follow up post added April 2nd, 2011 09:51 AM ------

Poking around a bit more - the return line actually goes to the filter rather than the tank. Any down side to running it this way?
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  #2  
Old April 2nd, 2011, 12:35 PM
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I installed mine in July 2001. It has a manufacture date of May 2001 on the attached stickers and paper work. Mine does have a return line. I have seen the return lines joined into the intake line before, but I like the idea of the line returning to the tank, sending warmed fuel back to the main tank. The Bosch VE pumps do pull more fuel than is required for injection. My 1981 Rabbit had a return line, and so does my '85 BMW as well as my'97 Cummins. All of them have Bosch VE injection pumps.

Dennis
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Old April 2nd, 2011, 12:47 PM
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Michael White
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Dennis,

Thanks - this is my first diesel, and I'm still in the learning stages. For now, I'm going to leave it as-is. It seems to work, plus I now have a fuel tank for a single line setup

Michael
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  #4  
Old April 2nd, 2011, 04:52 PM
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Jamie Austin
1992 110 Td5 CSW & 1989 MB G-Wagen
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Funnily enough, I was helping a friend change his fuel level sender on his 300Tdi 110 today, and his only has one fuel line. The sender unit has 2 unions, but one of them is blocked off.

You're correct in that the spill rail (or return) is just piped into the head of the filter.
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Old April 12th, 2011, 04:10 PM
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Jason Herring
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Whoops, posted in wrong thread. Nothing to see here :-)
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  #6  
Old April 12th, 2011, 09:51 PM
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John B.
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The return to the tank is safer in my opinion. If there is a leak anywhere and you get air in the system, the return to the tank allows it to self purge out. A return to the filter will trap the air.
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