200tdi into 2.5td 110..fuel pipe help please

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RouseSport

RouseSport

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25
Location
Lovedean Hampshire
I’ve fitted a 200tdi into my 110 which had the 2.5td. The engine is from a defender and came complete with everything needed to fit. However, I removed two fuel pipes to be able to take out the 2.5td complete, one from the fuel filter housing (female screw on) and one from the fuel pump(male screw on). Having fitted the 200tdi with its original fuel filter housing, there is no male fitting for my female fuel pipe and the fuel pump has the correct female fitting plus one extra malefitting...what’s that all about? Please help.
 

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It goes 10mm pipe from tank to lift pump, out of lift pump to filter, out of filter to front of FIP (belt end). Return 8mm, comes from number 1 spill pipe to rear of FIP , back to tank.
 
Last edited:
I think the older engiens ran the leak of fpipes back to the filter head, tdi is back to inj pump then back to tank.
 
lynall said:
I think the older engiens ran the leak of fpipes back to the filter head, tdi is back to inj pump then back to tank.
Click to expand...
So basically the pipe that went from the tank to the filter housing now goes straight to the lift pump!! And the original pipe that went to the pump just goes in the same place!
 
RouseSport said:
So basically the pipe that went from the tank to the filter housing now goes straight to the lift pump!! And the original pipe that went to the pump just goes in the same place!
Click to expand...
No.
If you look at the rear of your TDI FIP it has a double banjo fitting to take 1 pipe from number 1 injector leak off and another (8mm) pipe which is the return back to the tank.
The other pipe from the tank (10mm) goes to the lift pump, another pipe comes from the lift pump to the filter head, another pipe comes from the filter head and goes to the FIP (large banjo top front of the FIP).
 
So looking at this pic of a 90 converted to tdi. This connection has been blanked off! So the pipe that comes under the car on the drivers side to the tank, that went to the remote fuel filter housing...where does that go now? Sorry for all this.
 

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To the double banjo fitting rear of FIP (leak off pipe from number 1 injector goes there too).
It should be 8mm outside diameter, that pipe circled.
 
Number 1 injector isn't shown in that pic, there is a double outlet banjo on number 1 injector (number 1 is front of the engine).
The pipe from there goes to the double fitting rear of FIP with the one circled.
 
IMG_20191126_123655.jpg
return line going back to the tank, rear of FIP. See that yellow 6mm pipe? That goes to the same port on the FIP and the double banjo on number 1 injector. Some mods by me, yellow pipe instead of black? Clear pipe for flow and return so I can troubleshoot easier.
 
Dont forget do not mix up the banjo bolts, same size thread except the return one has a flow/pressure restrictor built into it.
 
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