300tdi Boost compensator banjo connection

[tdikid]

Hi Everyone!

This is my first post and of course it's asking for help!!
I have a 95 Defender 130 with a 300tdi engine which has been in the family since it was new ( was my father in laws). anyway..

Was driving to work and noticed fuel seemed to cut out at high-ish revs, but got worse as I got to work. Took a look under the bonnet and found the vac line from Turbo to the boost compensator diaphragm flapping in the breeze.:thumbsdown:

I've tried a local Land rover "specialist" and cant find where a replacement bolt could be sourced. New or used.

Below is a pic I stole from Google highlighting the bolt I need. (It took me a while to explain to spare parts man that I was not after the fuel banjo bolts)

93916

Can someone help me locate a spare?? Preferably around the Newcastle area but beggars can't be choosers!

Cheers

[Dopey]

I had exactly the same issue with one of my 300Tdi's.
I spent nearly an hour at Karcraft with Tim going through the catalogue trying to find the part and he couldn't get it on their catalogue at all.

I ended up reusing an old one that I had from another engine.
Maybe try a wreckers like Land vehicle spares at Silverdale.

Mike.

[tdikid]

I had exactly the same issue with one of my 300Tdi's.
I spent nearly an hour at Karcraft with Tim going through the catalogue trying to find the part and he couldn't get it on their catalogue at all.

I ended up reusing an old one that I had from another engine.
Maybe try a wreckers like Land vehicle spares at Silverdale.

Mike.
Cheers Mike,
I've tried a few wreckers around here with no luck but I'll keep on searching. Like you I have not been able to find one in any of the catalogs or parts diagrams anywhere.

Am I right in assuming it's a Banjo bolt and not a simple bolt?

[86mud]

Do you have a hose fitting place near by like Enzed or Pirtek? Try them

[tdikid]

Do you have a hose fitting place near by like Enzed or Pirtek? Try them
Good thinking Andrew.

There's one almost on my way home. I'll call in and ask.

[tdikid]

Do you have a hose fitting place near by like Enzed or Pirtek? Try them
Good thinking Andrew,

There's one almost on my way home. I'll call in and ask.

[tdikid]

Ok spoke to guy at Enzed. They didn't have what I was after. Apparently they don't sell many banjo bolts. Gave me the number of a local guy who works on a lot of injection pumps. Couldn't get through this arvo so will try again tomorrow.Also all wreckers don't seem to have it or at least the ones I've called.
Pretty big pain in the arse for such a small part...
Does anyone have any details on the bolt, thread, length etc? If I had one finding a replacement would be easier.

Cheers

[Dopey]

Cheers Mike,
I've tried a few wreckers around here with no luck but I'll keep on searching. Like you I have not been able to find one in any of the catalogs or parts diagrams anywhere.

Am I right in assuming it's a Banjo bolt and not a simple bolt?

Sorry mate, been busy and couldn't reply...
It is a banjo bolt, if I get the time tomorrow, I'll pull it out and measure it with a tpi gauge and let you know the results.


Maybe these part numbers might work,
Land rover part number: STC3597
Bosch part number: 1463456344
Volvo part number: 861514
Fiat part number: 9948516 and 9951014
Iveco part number: 93155977
Man part number: 81981500102
Renault part number: 5001830473 and 7701045337
Case International harvester part number: 9968181



But you would need to check before purchasing.....

These are numbers that I have got from old Bosch info on the fuel injector pumps, not sure if it the correct part at this time, but I will try and chase it up further.
Regards,
Mike.

[tdikid]

Your a bloody legend Mike.


I'll take a look at some of those part numbers and let you know how I go.


Cheers
Ben

[460cixy]

If you know the size and thread of the bolt just make your own there nothing more then a bolt with a couple of holes in it

[mox]

The original post describes this line form the turbo to the boost compensator diaphragm as a "vac line" (ie vacuum) It is actually a pressure line. As those who have put a T piece in this line are fully aware, the boost pressure only builds up with when revs and load are up somewhat. The maximum fuel injection rate for the revs are limited until air pressure builds up in the inlet plumbing past the turbocharger When pressure from it increases on this diaphragm, maximum fuel rate is increased as there is extra air to burn the fuel. Note the full boost standard setting allowed by the turbo wastegate on 300Tdi's is 15psi. ie absolute pressure is about 30 psi, double absolute atmospheric pressure of 15psi. However, there is not quite double the quantity of air entering the engine because compressing by the turbocharger heats and expands it. Purpose of the intercooler is to cool this air under pressure.


With this line off, motor is somewhat gutless as fuelling rate cannot increase with increase in load and boost pressure. If you then jammed diaphragm mechanism so maximum fuel could possibly be delivered all the time, power under full boost would be normal. Under low boost it would be increased but lots of black smoke due to insufficient air. Manufacturers settings have to comply with pollution regulations. However, a weaker than standard spring under the diaphragm allows the fuelling rate to increase earlier. Allows better acceleration - if you are not worried about the extra smoke.

[Dopey]

Just pulled the bolt out, here are a few pics of it....
Not sure at the moment if the part numbers that I posted last night are for the correct bolt?

Note that in the pic provided, there is a brass/bronze gauze filter pressed into the center of the bolt..

Mike.

[Dopey]

Note the markings on the bolt head...
The bottom row is 344g ( if that means anything?).
Mike.

[Dopey]

Also....

[tdikid]

Cheers to all!!

Bloke an Enzed yesterday gave me the number for Rosier Diesel Injection Services in Kotara. Gave him a call and he knew straight away what I was after. Just got back and the legend there gave me a bolt and 2 new copper washers for free!!

It's not the exact same as standard as it doesn't have the filter but said shouldn't be a issue. I'll just remove the cover in a month or so to make sure there's not any crap getting in.

Thanks again to all who helped, especially Mike for pulling his pump apart to help out.

Take the rest of the day off. Tell your boss I said so. Haha

Ben