Fuel Lines

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Just about at the stage to put fuel lines back on to my 110 rebuild. I have these two which came with it but have not got a clue as which way they go back on as they were off when I got the vehicle. They have Obvious bends in them where they have ran along chassis.
Cant find any Instructions or Videos on youtube . Anyone Fitted a full set of fuel lines before.
 

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border said:
Just about at the stage to put fuel lines back on to my 110 rebuild. I have these two which came with it but have not got a clue as which way they go back on as they were off when I got the vehicle. They have Obvious bends in them where they have ran along chassis.
Cant find any Instructions or Videos on youtube . Anyone Fitted a full set of fuel lines before.
Click to expand...

Looking at the photos, I think the return is the one in the second photo, with the banjo bolt in it. The return should be a smaller diameter too.

Personally, I removed my nylon fuel lines because they left me stranded with an air leak. It didn’t help that it was during the “beast from the east” last year too!

I went with 5/16” bore rubber fuel hose.
 
mick 1986 said:
Looking at the photos, I think the return is the one in the second photo, with the banjo bolt in it. The return should be a smaller diameter too.

Personally, I removed my nylon fuel lines because they left me stranded with an air leak. It didn’t help that it was during the “beast from the east” last year too!

I went with 5/16” bore rubber fuel hose.
Click to expand...
Yes one is a smaller size. So the return is smaller. If I can figure which part of the tank the return connects to ? and where does it connect in engine, and same for other pipe, I might get the idea of where it runs along chassis rails unless I can find a Diagram or How To Guide somewhere.
 
border said:
Yes one is a smaller size. So the return is smaller. If I can figure which part of the tank the return connects to ? and where does it connect in engine, and same for other pipe, I might get the idea of where it runs along chassis rails unless I can find a Diagram or How To Guide somewhere.
Click to expand...

Yes the smaller is the return. It should connect to a banjo bolt on the rear of the fuel pump (this is what the connector is for in the photo I pointed out). The banjo bolt has a tiny hole in it, don’t try and open the hole up! It will then head up to one of the injectors. The other end connects to the plate in the top of the fuel tank.

The feed pipe goes from the pickup tube in the tank side, across the tank and stays with the return line, all the way to the engine bay. Once in the engine bay, the feed pipe connects to the lift pump.

Mine ran along drivers side chassis rail, from just behind the front axle, to just in front of the rear axle.

There should be a short length of pipe from the lift pump to the fuel filter, then the fuel filter to the injection pump (different banjo bolt, same style as rerun line just bigger hole). If you get to a point where your struggling, I can take a few photos of mine.
 
mick 1986 said:
Yes the smaller is the return. It should connect to a banjo bolt on the rear of the fuel pump (this is what the connector is for in the photo I pointed out). The banjo bolt has a tiny hole in it, don’t try and open the hole up! It will then head up to one of the injectors. The other end connects to the plate in the top of the fuel tank.

The feed pipe goes from the pickup tube in the tank side, across the tank and stays with the return line, all the way to the engine bay. Once in the engine bay, the feed pipe connects to the lift pump.

Mine ran along drivers side chassis rail, from just behind the front axle, to just in front of the rear axle.

There should be a short length of pipe from the lift pump to the fuel filter, then the fuel filter to the injection pump (different banjo bolt, same style as rerun line just bigger hole). If you get to a point where your struggling, I can take a few photos of mine.
Click to expand...
Thanks Mick, Got a bit of an Idea in my head now, I didn't imagine them running along side each other. So the return to plate on top of tank, so does the Feed go to pipe on Sender ?
 
border said:
Thanks Mick, Got a bit of an Idea in my head now, I didn't imagine them running along side each other. So the return to plate on top of tank, so does the Feed go to pipe on Sender ?
Click to expand...

Yes, return to plate on top and feed to pick up on sender. Give me a shout if you get stuck with any of it.
 
border said:
Thanks, never thought about those ones, watched a L R vid the other day and the bloke just heated them up with a Lighter and shoved them on.
Will get some
Click to expand...

Yeah that’s what I would be doing if I used the nylon fuel lines. They don’t need any clips. I used stainless jubilee clips at the tank end and proper fuel line clamps in the engine bay.
 
The reason for using fuel line clips is they compress all the way around, jubilee clips don't compress under the screw part, they put pressure there which can crack and distort the part you are trying to fix the pipe to, the plastic pipes are good if they are pre formed but I much prefer rubber when making up fuel lines.
 
nobber said:
The reason for using fuel line clips is they compress all the way around, jubilee clips don't compress under the screw part, they put pressure there which can crack and distort the part you are trying to fix the pipe to, the plastic pipes are good if they are pre formed but I much prefer rubber when making up fuel lines.
Click to expand...

I prefer the rubber fuel lines too. They are more robust and don’t usually give the problems of letting in air.

The reason for the stainless jubilee clips at the tank end, were metal pipes to clamp the rubber onto, and the ****e that gets up around the top of the tank would ruin the standard fuel line clamps. In the engine bay I have proper fuel line clamps.
 
Well please forgive me but Ill be Dammed if I can work this out. but then realised that these Original lines return and feed are going up to a different engine then the original, it now has 300tdi in, but suppose they can be modified to fit.
Anyway photos of it and original connectors.
Number 1 comes from the rear of Injection pump, Number 2 comes from Lift Pump, and number 3 comes from Injection pump to First Injector.
Old connectors either side which I will change for new. do I need these to fit to the pipes on Tank ??
Some photos of yours Mick would be great if you get time.
 

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The first photo,
1: fuel filter outlet to injection pump.
2: lift pump outlet to fuel filter inlet.
3: return line from injection pump and injectors, this is where your banjo should connect on the smaller return fuel line.

Photo 2,
The connector on the right looks like a 200tdi lift pump union and bent pipe. Remove the spiral wrap and see if you have a 90 deg bend on a piece of tube. If so, it’s for a 200tdi and not needed for the 300tdi.

Photo 3,
The snapped union looks like the top of the tank return line connector.

Photo 4,
Fuel pickup. This needs to connected to the lift pump with the large diameter fuel hose.

Photo 5,
Return to tank. This needs connecting to the injection pump union, using the small diameter pipe.

The fuel pipes should fit straight on, with the exception of the tank to lift pump connection. The 200 and 300 use different lift pumps, and pipes/unions. Everything else would be good to go.
 
This has got me thinking......

LR 200tdi motor. There are a couple of repairs before the lift pump (pipe from tank). I like the idea of replacing them with a single piece of clear pipe.

What is the best connector from the plastic pipe to a clear piece of fuel pipe?

5/16 fuel pipe?
 
bluehaze said:
This has got me thinking......

LR 200tdi motor. There are a couple of repairs before the lift pump (pipe from tank). I like the idea of replacing them with a single piece of clear pipe.

What is the best connector from the plastic pipe to a clear piece of fuel pipe?

5/16 fuel pipe?
Click to expand...

Mine is just pushed onto the steel pipes, no clips or clamps. I had to heat it up with hot water as 5/16 is ever so slightly too small. It’s very tight and doesn’t leak now. I need to take some photos for @border today, so I will tag you in them too.
 
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