Fuel Leak off Pipe Fittings 2.5 Tdi 90 Help Needed Please

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M

Mepps

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My First Landrover Defender - First Time using a Forum
1992 2.5 Tdi - Requiring lots of work

When I picked my "new" Landrover Defender 200Tdi 90, some fittings where missing from engine so I am slowly working my way using workshop manuals etc.
No experience with Landrover engines but looking forward to seeing if I can get engine to run and eventually use Defender as my daily.

Question 1 (If anyone could assist please)

Ref: Banjo Fitting & Part number - Fuel leak off pipe connection to Fuel injection pump
I have attached photo
Landrover 1992 Fuel Leak off pipe.jpg
IMG_20240419_121433879.jpg
 
Last edited:
I have purchased a full set of fuel lines & the one odd spot is what you are referring to.
When I get frame painted I am assuming I will have same question.
 
These are the diagrams I have in my parts manual. I would assume a 200tdi is the same as the 2.5. As most changes came in with the 300tdi.

IMG_5642.png


IMG_5643.png
 
Be aware that the fuel feed banjo bolt has a larger orifice than the return banjo bolt. They look identical when fitted to the fip and are the same head size and thread size just the internal bore is smaller on the return bolt.
 
Hello, thank you for reply & information. I have diagrams attached. As you will see , diagram does not identify or show the banjo bolt size I am looking for. If I find part number, I will post on site as it looks to be a tricky one to locate.
Thanks anyway
 
Attached additional photo. Connects to Fuel injection pump.
Banjo bolt size and part number required if anyone has information, please share.
Thank you
IMG_20240419_163453185.jpg
 
I think you need STC3597, which is a banjo bolt with a very small hole in it. I don't know the size/pitch, but its a special bolt because the pinhole diameter is important.
The pinhole is only there to allow tiny bubbles of air to leave the injection pump back to the tank so it self bleeds, while still allowing the pump to build pressure.
I've come across a leyland diesel engine where the previous owner put a normal sized banjo in this place, and the engine ran very badly.
 

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Also worth verifying the spill rail banjo bolts on the injectors have normal sized holes in them and are all the same. In the bad engine, the owner had put the special bleed banjo in a diesel injector by mistake, and it caused bad problems for that 1 cylinder...

I cant remember if landrover 200tdi has the same thread size injector banjo bolt and injection pump banjo bolts, but they are on a JCB...
 
As above, the bolt has a tiny hole in it to maintain the internal pressure on the pump. Its non standard.

Which stuffs up my usual suggestion of getting a longer bolt and doing a double banjo, as you won't be able to get the bolt longer.

People break 300tdi engines often - I would suggest trying to get a second hand part OR just using a standard banjo with the special bolt and putting a tee in the line a bit later.
 
MrF said:
I think you need STC3597, which is a banjo bolt with a very small hole in it. I don't know the size/pitch, but its a special bolt because the pinhole diameter is important.
The pinhole is only there to allow tiny bubbles of air to leave the injection pump back to the tank so it self bleeds, while still allowing the pump to build pressure.
I've come across a leyland diesel engine where the previous owner put a normal sized banjo in this place, and the engine ran very badly.
Click to expand...
Hello,
Thanks for taking the time to share information and descriptions. Much appreciated.

The banjo bolts into injector are original bar one which I checked against the other three. All ok & I renewed cooper washers.

Thanks again
 
julianf said:
As above, the bolt has a tiny hole in it to maintain the internal pressure on the pump. Its non standard.

Which stuffs up my usual suggestion of getting a longer bolt and doing a double banjo, as you won't be able to get the bolt longer.

People break 300tdi engines often - I would suggest trying to get a second hand part OR just using a standard banjo with the special bolt and putting a tee in the line a bit later.
Click to expand...
Hello,
Thanks for suggestions. Great to pick up these tips and explanations as to workings of parts.
If I find part and all works out, I will make sure to share should anyone else have same challenge as myself.
 
MrF said:
I think you need STC3597, which is a banjo bolt with a very small hole in it. I don't know the size/pitch, but its a special bolt because the pinhole diameter is important.
The pinhole is only there to allow tiny bubbles of air to leave the injection pump back to the tank so it self bleeds, while still allowing the pump to build pressure.
I've come across a leyland diesel engine where the previous owner put a normal sized banjo in this place, and the engine ran very badly.
Click to expand...
Hello,
Just posting update and to let all know I ordered part STC3597 . Yes it has smaller pin hole and inner mesh. I have since fitted and after many years of jeep sitting idle, engine turned over and started straight away. reving high but we will get round to sorting at a later date. Main thing is Engine now runs .
Thanks everyone for all the help .Close up photos of bolt attached
 

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