200 tdi converting

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larrynumber1 said:
ERR1200 FUEL INJECTOR BANJO BOLT | shop | www.lrseries.com | L. R. Series banjo&page=1

This what ya after??
Keep us posted langers iv my 200tdi sittin outside ready to go just waitin on 90 to pass mot first!

Have you fitted your rear crank oil seal yet?
Click to expand...

I'm not sure :confused: Is that the one that goes into the back of the injector pump? There are about 4 or 5 different size and shapes of banjo bolts for various parts of the fuel system I think.

In the end I didn't change the rear crank oil seal, as there were no signs of any leaks at all! I didn't want to risk taking it out and refitting my new part (which turned out to be a Britpart one!) and then it leaking subsequently. I was advised to leave it if there weren't any leaks, so we'll see :p. The engine is now in the 110, and is all hooked up with the exception of this one fuel line. :D Did the welding part today (my first ever welds), which was great fun. I'll probably put up a report once it's all running, along with some problems I ran into and how I fixed them.

So far it's been a challenging, but far from impossible job. It's a huge learning experience as I've never done anything like this before - the most complex work I'd done before this was changing the head gasket on a 1.2 Fiat Punto engine, but I've not really run into any problems that couldn't be solved with a bit of chin stroking and some advice from the chaps on here. :cool:
 
yeah it aint agreat pic for identifyin exactly what it is!

thinkin of doin the same myself! i have a genuine seal here but when i picked up the engine he told me its been serviced for oil and all filters only 300 miles ago! and the bill is runnin quite high without changin the oil un-necessarily! but maybe i could use same oil again??:confused:
 
Up to you mate, you could re-use the oil if you are careful about draining and storing it, and if you trust your man's word about when it was last changed. I know what you mean about cost though, it's cost me a fair bit more than I expected it to, though that's partly my own fault. Mine was last serviced about 4,000 miles ago so it definitely deserves some fresh oil and filters. :)
 
yeay i suppose i could give it a try, guy seems trustworthy but would be a shame to not use seal when i have engine out! 4000 deserves a service alright but at least you will know its runnin right
 
Not a very good pic, but anyway, here's a shot of the back of my injector pump, showing the bolt hole and the pipe that needs connecting there I think. I need to know the part number of the banjo bolt that goes there, it's the last thing on my list of things to do! :)

IMG_4063-1.jpg


Cheers all :D
 
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Ok I think I've narrowed it down to part number ERR 886. If anyone can confirm this it'd be great. I also think I'll have to order direct from LR, since I can't find anywhere else that sells it.
 
Well, the bolt arrived (finally) and guess what... it's the wrong part.

The bolt is wayyyy too small for the hole on the back of the injector pump. It even looks much smaller than the illustration on the parts diagram. At a loss to finding the right one now...

I've fitted the rad/intercooler and rebuilt the front of the 110, but I'm having trouble fitting the rad hoses - they just don't seem to fit under the fan. What I want to work out is whether I will actually need the viscous fan. We're doing an expedition/trip to Morocco in a few weeks time, so I'm worried that without one, temperature might be a problem. If I remove it and fit a decent electric or twin electric fan, will it be OK? I have just fitted a brand-new radiator.

Cheers all,

Langers, the world's slowest mechanic :D
 
I didn't fit the fan to my 200tdi when I did the conversion - so far I've had no problems with overheating. BUT - that's in this country! I bought an IR thermometer and even on the hottest days, the temperature of the radiator pipes doesn't seem to go much over mid-60's.

On my "to do" list is fitting an electric fan. It may not come on much, but it'll be nice to know it's there "just in case".

So if I was you, I'd get the radiator hoses sorted without the fan fitted - and then fit an electric fan once it's all up and running.
 
instantsquid said:
I didn't fit the fan to my 200tdi when I did the conversion - so far I've had no problems with overheating. BUT - that's in this country! I bought an IR thermometer and even on the hottest days, the temperature of the radiator pipes doesn't seem to go much over mid-60's.

On my "to do" list is fitting an electric fan. It may not come on much, but it'll be nice to know it's there "just in case".

So if I was you, I'd get the radiator hoses sorted without the fan fitted - and then fit an electric fan once it's all up and running.
Click to expand...

Yeah I know it would be ideal to have both, but how can I get the hoses to fit around the fan? I have all the original pipes from both vehicles but they go straight into the fan.
 
Which hose interferes with the fan? The top one should go over it, the bottom one should go under it. I think some of the guys who kept the viscous fan have trimmed the blades so they don't hit anything!

As I said before - leave the fan off for now and get the engine running. An electric fan can be made to fit the space available once it's all going.

Ian.
 
Oh right sorry, misread that. Ok, will try that tomorrow. The top hose goes well over the top, no problems, but the bottom one seems to be way off. Oddly, I didn't have any problems with the fan hitting the power steering box, as other have had. Perhaps mine is different in some way. :confused:
 
Ok, I've found the banjo bolt that I need that fits the back of my injector pump, turns out it's the same as the one that goes in the top :doh:

Still, I need to find where I can order one of these puppies;

IMG_4067.jpg


Cheers all, literally the last bolt I need before I can start her up (hopefully!) :D:D:D
 
Cheers for the help mate but I've already got that page, and I assumed (tell me if you wouldn't) that the bolt I needed was number 12, part no ER886 - when I ordered this from LRseries, it arrived and was way, way too small - completely wrong, but their packaging and documentation stated I'd been sent the ER886 part. :doh::doh::doh: :confused::confused::confused:
 
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