300tdi conversion q's re:fuel lines - Defender Source
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  #1  
Old July 30th, 2015, 11:04 PM
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Eric Wages
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300tdi conversion q's re:fuel lines

Hi folks,

The end is in sight of for my 300tdi conversion. Tonight, I started hooking up the hoses and whatnot and noticed that the fuel lines for the 19J are in a different place. From first glance, it looks like the return and feed line from the tanks are too short to where they hook up to the lift pump and and injection pump, and additionally, the press-on lines to/from the filter are tight.

Questions:

1. Anyone have any tips on extending the lines with compression fittings to/from the fuel tank?
2. Is it common to cut off the slip-on nylon lines to/from the filter and put on new fuel lines? Any recommendation on sizes?

Thanks!
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  #2  
Old July 30th, 2015, 11:10 PM
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Brian Kandefer
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Stock mounting location on a 300 is on the rhd wing. I'll post a pic if I can find one. That might help? Not sure
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Old July 30th, 2015, 11:14 PM
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Eric Wages
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Quote:
Originally Posted by Brewie212 View Post
Stock mounting location on a 300 is on the rhd wing. I'll post a pic if I can find one. That might help? Not sure
Ah, thanks for that photo. Yeah, that would be great, except I need to reuse the power steering reservoir in that location. I'm thinking that replacing those lines to/from the fuel filter may be easier.
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Old July 30th, 2015, 11:20 PM
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Brian Kandefer
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Gotcha, sorry that didn't help. Can you just replace the hard plastic line with regular fuel line? The pressure shouldn't be enough to affect the line? I honestly don't know, but would typically just replace the entire line rather then splicing. Anyway good luck and looking forward to see what your next project is.
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Old July 30th, 2015, 11:29 PM
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Supply lines are 3/8" nylon tubing. Return is 5/16". All cheap and easy to get. The stock connectors are installed by heating the tubing until it is soft and pressing it on. It is not that hard to do but you may need to try a couple of times to figure out the technique. You can also replace with compression fittings.
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  #6  
Old July 30th, 2015, 11:32 PM
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It all runs at such a low psi that it's hard to say it matters how you do it. I would follow Red's suggestion.
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Old July 30th, 2015, 11:38 PM
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Eric Wages
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Quote:
Originally Posted by Red90 View Post
Supply lines are 3/8" nylon tubing. Return is 5/16". All cheap and easy to get. The stock connectors are installed by heating the tubing until it is soft and pressing it on. It is not that hard to do but you may need to try a couple of times to figure out the technique. You can also replace with compression fittings.
Thanks for the tips!

Thoughts on how to extend the nylon return line? Or just make another section of nylon with compression fittings and do a joint that way? Or replace the whole line all the way to the tank?
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Old July 31st, 2015, 12:15 AM
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Just use rubber fuel line and hose clamps to extend.
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  #9  
Old July 31st, 2015, 09:15 AM
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Quote:
Originally Posted by Z.G View Post
Just use rubber fuel line and hose clamps to extend.
I've been running this way for a couple of years - no leaks so far.
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Old July 31st, 2015, 09:33 AM
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Quote:
Originally Posted by michael67 View Post
I've been running this way for a couple of years - no leaks so far.
Have you been doing this specifically on that nylon line directly, or did you add a male/male barb connection and clamp to that?
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Old July 31st, 2015, 10:06 AM
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Eric:
The original fuel lines on most 300TDI Factory setups use a push on lock back at the tank, similar to the VW Jetta and a lot of other manufactured vehicles.
In order to avoid sucking air into the fuel system, I generally replace all or part of the fuel fittings with barbed metal ones and then use a high quality "rubber" fuel line with the euro-style hose clamps that have solid metal bands.

I have reused nylon plastic lines and put on new olives and fittings, with marginal success.
If you end up kinking a nylon line it is hard to see the split that often results letting air get sucked in making the engine run poorly or not at all.

If memory is correct the 19J uses 1/2" fittings and the 300TDI uses 14mm X 1.5 under the hood.
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  #12  
Old July 31st, 2015, 11:56 AM
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Quote:
Originally Posted by TheOneTen View Post
Have you been doing this specifically on that nylon line directly, or did you add a male/male barb connection and clamp to that?
I added the barb. I think the nylon line may be a bit too slippery and flexible.
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Old July 31st, 2015, 01:25 PM
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Move the PS reservoir to the other fender, there should already be holes in the fender lip for it.
Then put the fuel filter in its proper location, as someone previously mentioned.
You'll also need a bracket then to help support the filter on the fender (there's already a hole in the wheel well for the correct location).

Do the set up correctly, you won't regret it.
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Old August 1st, 2015, 05:05 PM
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Eric Wages
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So, the fuel filter has been taken care of, but now I'm scratching my head trying to figure out the fuel in/out lines.

As a reminder, this is a 19J->300TDI conversion, so the lines to/from the tank don't line up and have the wrong fittings. Best I can tell (see attached), the lift pump and the return from the injector pump both have 5/16" lines. What I can't find is what's the magic barbed fitting that I can use to mate to these? Does anyone know the thread pitch? Should these be flared or not? Hopefully no, so they can be removed/cleaned up.

Of note, the output of the lift pump to the fuel filter has a barb on the compression fitting and it sure looks like it's the same as what I'm looking for, but I can't find a PN or any info on what this should be (Imperial? Metric? NPT? Straight?)

If not flared, I can just cut the nuts/ferrules off, and redo with US fittings.

Your help is welcomed, as always.
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