Spill Return Lines - 200TDI - Defender Source
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  #1  
Old April 9th, 2014, 06:58 PM
javelinadave
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Spill Return Lines - 200TDI

One of my spill return line is leaking. Can I just swap out the section with a line from Autozone or do I need to buy a whole new shebang?
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  #2  
Old April 9th, 2014, 07:04 PM
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Quote:
Originally Posted by javelinadave View Post
One of my spill return line is leaking. Can I just swap out the section with a line from Autozone or do I need to buy a whole new shebang?
I suspect that the Vatozone repair would work, as there isn't much pressure there. I decided to buy the whole new shebang from Trevor. It's an updated design, with softer more flexible lines that are (according to Interweb rumor) less likely to transmit vibration to the banjo bolts and allow them to loosen. He also has new banjo bolts and copper sealing washers available as well.

I haven't installed this yet but I have had problems several times with my existing setup with the banjo bolts loosening.
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Old April 9th, 2014, 07:05 PM
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I replaced mine with Viton hose. There's an old post from Overlander that has the specs. Let me see if I can find it for you...
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Old April 9th, 2014, 07:12 PM
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Mine has the cloth covered rubber tubing. It is leaking between the front cylinder and the second one back.
Fix the oil leaks and get a fuel leak. Curse these things!!!!!
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  #5  
Old April 9th, 2014, 07:15 PM
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Trevor has them at Rovahfarm for cheap
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  #6  
Old April 9th, 2014, 07:45 PM
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Last one I fixed I used some tubing from McMaster. I have had bad luck with the cheap aftermarket replacement "spill return" sets. Damn things are invariably made too short and you end up pulling the damn tubes trying to stretch them so they will bolt to the injectors.
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  #7  
Old April 9th, 2014, 08:08 PM
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Dave:
Since your locals will say 200 what? Land Cruiser?
Did you try the Toyota Dealer?

Go buy some injector spill over line for a Mercedes Diesel 1965 - 2002.
The Mercedes dealership will have a spool of it in their workshop.
Just tell them you need it for a 1984 300D.
It will work just fine.
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  #8  
Old April 9th, 2014, 08:18 PM
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Originally Posted by rdavisinva View Post
Dave:
Since your locals will say 200 what? Land Cruiser?
Did you try the Toyota Dealer?

Go buy some injector spill over line for a Mercedes Diesel 1965 - 2002.
The Mercedes dealership will have a spool of it in their workshop.
Just tell them you need it for a 1984 300D.
It will work just fine.
Thanks Robert! There is a MB dealership right down the road from me.
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  #9  
Old April 10th, 2014, 02:14 PM
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MB hooked me up, no more leak as of this moment.
Thanks again Robert!
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  #10  
Old April 10th, 2014, 02:42 PM
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Quote:
Originally Posted by sonoronos View Post
I replaced mine with Viton hose. There's an old post from Overlander that has the specs. Let me see if I can find it for you...

Yes. replace with viton. just get a length and cut it yourself to fit. if the MB shop gave you rubber, order viton now and replace it. if you don't know what they gave you, order viton now and replace it.

------ Follow up post added April 10th, 2014 02:43 PM ------

PS, order a little extra and keep it in your onboard spares. you never know when the day will come when you nick a return line.
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  #11  
Old April 10th, 2014, 02:47 PM
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Quote:
Originally Posted by javelinadave View Post
MB hooked me up, no more leak as of this moment.
Thanks again Robert!
Dave:
Excellent...

Quote:
Originally Posted by Overlander View Post
Yes. replace with viton...
Mark:
Viton is top of the line and a must for B100 or WVO.
If you find the link of where to buy it in length, please share.
We are converting another 110 to the Mercedes OM617 the summer, complete with WVO conversion, so will need some viton spill over line.
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  #12  
Old April 10th, 2014, 02:57 PM
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you can buy it buy the foot on ebay. there's also several WVO shops that sell it. the spill hose is 3.2mm ID (1/8"). 4' should be plenty along with spare.

http://www.greaseworks.org/index.php...unc=view&pid=5

http://www.dudadiesel.com/viton.php?...ng_id=17:18:US
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  #13  
Old April 10th, 2014, 03:02 PM
javelinadave
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Mark,
You bought 1/8"?
No issues pushing it onto the fittings?
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  #14  
Old April 10th, 2014, 03:04 PM
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nope. 1/8 is 3.2mm. unlike the oem hard nylon spill lines, the viton is more flexible than rubber.
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  #15  
Old April 10th, 2014, 03:09 PM
javelinadave
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Originally Posted by Overlander View Post
nope. 1/8 is 3.2mm. unlike the oem hard nylon spill lines, the viton is more flexible than rubber.
What size did you order?
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  #16  
Old April 10th, 2014, 03:17 PM
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it's been a while, but pretty sure I got 4' from dudadiesel. good time to order for your main pump and return lines too.

1/8" Fluoroelastomer Hose• 100% Biodiesel Compatible, Priced Per Foot• Max 400F, Max 100 PSI at 70F• 1/8" ID, 0.23" OD, 1.33mm Wall
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  #17  
Old April 10th, 2014, 03:22 PM
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Thanks!
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  #18  
Old April 10th, 2014, 03:24 PM
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Now go do great things
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