200 tdi fuel filter

[dan]

I just converted my 2.5 110 to a 200tdi. It looks like the banjo bolts(or whatever they are called) are smaller than the holes in the 200tdi fuel filter. What do I do? Buy bigger ones and fit them, or stick with the 2.5 n/a fuel filter? Thx.

[Strange Rover]

You can go either direction.

I don't know enough about these engines to say for sure but logically the flow of fuel isn't much different between the two. At least not enough that it's going to create an issue if you stick with the stock size fuel filter. The bigger filter can in theory flow more/hold more dirt but that's where the difference ends. They serve the same purpose and I'd be willing to put money down that the 2.5 filter is just fine (assuming it's new and not already gummed up).

That's my thoughts. If anyone knows better, feel free to chime in since I don't know all that much about defenders specifically. Maybe it won't work but I see no reason why it wouldn't. Only thing is you'll have to remember for the future, when you go to buy a new one and the guy at the counter asks what engine you have. If you tell him it's the 200tdi he'll end up giving you another 200tdi filter. That's literally the only hardship I could see coming of using the stock size 2.5 filter and I'm sure it's something you don't mind living with :)

Cheers Dan

[red90]

You should change to the correct filter. The NA filter will not filter to a proper level. The injector hole in the NA is many times larger than the holes in the TDI.

In addition, the piping should be different. The TDI should return directly to the tank to properly self purge of air. The NA recirculates to the filter.

My suggestion is to get a Stanadyne FM-100 filter head and use a 6"-2 micron filter. The FM-100 head fits in the stock location and will only require some tubing fittings to connect to it. The filtration is much better which has been shown to drastically increase injector nozzle life and the filters are not expensive and easy to find.

[Strange Rover]

You should change to the correct filter. The NA filter will not filter to a proper level. The injector hole in the NA is many times larger than the holes in the TDI.

In addition, the piping should be different. The TDI should return directly to the tank to properly self purge of air. The NA recirculates to the filter.

My suggestion is to get a Stanadyne FM-100 filter head and use a 6"-2 micron filter. The FM-100 head fits in the stock location and will only require some tubing fittings to connect to it. The filtration is much better which has been shown to drastically increase injector nozzle life and the filters are not expensive and easy to find.

Oh so they're actually completely different? OK then yeah in that case, definitely change to the proper one.
They're even piped differently?.. wow, that's quite interesting. I was under the impression that all Rovers just used normal inline fuel filters. Learn something new all the time.

If it was just a normal inline filter it wouldn't have mattered so much, if at all.

[red90]

Diesels require much finer filtration than gasoline engines. The pressures are very high and the injector hole sizes very small. In the TDI, the nozzle holes are around 200 micron. Stock TDI filters are in the 15 micron range.

CAT did a massive study on pump and injector life with different levels of fuel filtration. They found substantial increase in component life with the use of 2 micron filtration.

[Strange Rover]

Great information, thanks. Always want to have a good quality filter for sure, even in a gas engine.. I was only thinking that having them different physical sizes would not be a dealbreaker in Dan's situation. Assuming they had the same method of operation and the filter was of the same basic quality, either one would have worked. So long as they're both meant for diesel engines.

I feel perhaps a bit stupid to ask this but was the 2.5 in the 110 not also a diesel engine? For some reason I thought it was a 2.5 non-turbo diesel. So would it not still be high pressure/small injector hole size/etc? My knowledge of diesel Rovers is minimal, if I'm honest. From the way he worded it, it sounded as though they were both set up/plumbed the same way in his truck (possibly due to the swap?) the only difference was the banjo bolts not fitting the new filter.

Hopefully I'm not asking too many questions, I just like to learn all these things and keep my brain active. My background is aircraft electrical (Do your worst, Mr. Lucas, I guarantee it's no worse than Mr. Sikorsky) I bought my Rover like a year ago to force myself to get some hands-on with the mechanical goodies. Ever since owning my RRC, I've got the bug. No doubt there are more Rovers in my future.

Best of luck, Dan. I'm sure it won't be a difficult fix.

***EDIT: I looked it up and the 2.5 is a petrol engine. Don't use the petrol filter on the diesel engine, that wouldn't be good.

[red90]

The 2.5NA is an indirect injection engine. It uses a lower pressure injection system (2000 psi) with a single injection hole for each cylinder. The holes are large and not injecting into the cylinder makes them quite tolerant of solids in the fuel.

The 200TDI is direct injection at higher pressure (4200 psi) and each injector has 5 holes. Injecting directly into the cylinder exposes the tips to higher temperatures.

As to the different plumbing, the injection pumps are different manufacturers and work differently.

[Strange Rover]

Very cool. So only one is direct injection. I see.