300tdi Injector Spill Rail Banjo Bolts and Copper washers

[towe0609]

I have a leak from the No 2 Injector banjo bolt on the spill rail on my 300tdi Defender.

When I took the bolt off I found it was a 'home-made' banjo bolt ... made from a CAT branded high tensile bolt!

Today the new bolts arrived from the UK supplier ... supplied are 4 banjo bolts, 4 flat copper washers, and 4 concave/convex copper washers ... if you know what I mean.

Which washer goes on which side of the V shaped fitting?

One of the flat washers has a slightly smaller external diameter than the other 3 ... is there anything to that? Does the smaller washer need to go on a particular injector?

[AK83]

... supplied are 4 banjo bolts, 4 flat copper washers, and 4 concave/convex copper washers ... if you know what I mean.

Which washer goes on which side of the V shaped fitting?

One of the flat washers has a slightly smaller external diameter than the other 3 ... is there anything to that? Does the smaller washer need to go on a particular injector?

Not sure why yours are different.
I did my injectors a few months back, and renewed all the washers too.
The kit came from a UK supplier too(can't remember if it was Craddocks or Paddocks).

All spill washers were the same type/size (all flat) and all the injector washers were the same type/size too.
I do remember that the injector washers had a raised ring around them which must be a compression seal.

None of the spill washers were curved in any way.
And going by the parts list, the listed part No. for all the washers is the same at ERR1304. (ie. all 8 washers should be the same).

[Roverlord off road spares]

should all be the same, possible a QA problem????

[towe0609]

This is apparently a photo of the genuine product, and it looks like those convex/concave washers are 'normal'

STC3297 | BANJO BOLT SET 6MM FUEL INJECTOR 2-300TDI | Land Rover | Discovery 1 - 1989 to 1999 | Britcar (UK) Ltd (http://www.brit-car.co.uk/product.php/92941/1976/banjo_bolt_set_6mm_fuel_injector_2_300tdi)

[Roverlord off road spares]

This is apparently a photo of the genuine product, and it looks like those convex/concave washers are 'normal'

STC3297 | BANJO BOLT SET 6MM FUEL INJECTOR 2-300TDI | Land Rover | Discovery 1 - 1989 to 1999 | Britcar (UK) Ltd (http://www.brit-car.co.uk/product.php/92941/1976/banjo_bolt_set_6mm_fuel_injector_2_300tdi)

One of the flat washers has a slightly smaller external diameter than the other 3 ... is there anything to that? Does the smaller washer need to go on a particular injector?
I was referring to this.

[towe0609]

Ahhh OK ... sorry. Yes I think your right re QA on the smaller washer. Its more the concave/convex ones that has me stumped. Anyway I decided to just replace the banjo with 2 regular M6 flat washers I had here anyway and torqued to 10Nm as per spec and it leaks no more. So sorted, but would still be keen to learn in what way those convex/concave washers are used.


One of the flat washers has a slightly smaller external diameter than the other 3 ... is there anything to that? Does the smaller washer need to go on a particular injector?
I was referring to this.

[AK83]

...Anyway I decided to just replace the banjo with 2 regular M6 flat washers I had here anyway and torqued to 10Nm as per spec and it leaks no more. So sorted, but would still be keen to learn in what way those convex/concave washers are used.

I was going to suggest the same.

Only recently I purchased a box kit of about 500 copper washers of various sizes off ebay, which I can see would have contained ideal replacements.
Standard typical flat types.
This was well after I did spill pipes tho but now.

Like I said I did mine only a few months ago(maybe July or so) .. all 8 were flat(10 came in the pack). No leaks.
I only estimated my banjo torque values by hand/feel tho.

Note that I also did my injectors at the same time, and the washers they use are definitely special types with a compression ring bump on one side of the washer.

If I ever have to undo/redo my spill rails again, I'm just going to use the copper washers I now have in that kit I got from ebay.

[towe0609]

Only recently I purchased a box kit of about 500 copper washers of various sizes off ebay, which I can see would have contained ideal replacements.
Standard typical flat types.


I bought that set too ... was $50 or so ... unfortunately mine was damaged in the post, and when it arrived the plastic box was smashed, some of the washers were missing (holes in the plastic wrap) and the rest were just swimming around in the bag. Took me hours to sort them back into their sizes. The vendor gave me a $20 refund which I used to buy a $5 plastic box at bunnings ... so all good now. They are the washers I used on the spill rail. I needed the banjo bolt ... and the cheapest way I could find to buy one was in a set of 4 with washers. Some more random spares added to the collection. If any leaks develop I'll just use washers from the kit too.

[AK83]

I bought that set too ... was $50 or so ... unfortunately mine was damaged in the post, and when it arrived the plastic box was smashed, some of the washers were missing ....

LOL! same here.
I collected it from the LPO all nicely wrapped and proceeded to rip the wrap up as I was nearing my bins(wrap straight into the bin kind'a idea).
As I was doing the wrap, I could hear a soft faint 'tinkling' of metal but it was so soft it sounded a distance away .. thought nothing of it.

Into the house to change and dump stuff here and there .. place plastic tray of washers in study . I hear the faint tinking metal sound again, turn around and I see a trail of all the really small(5mm or whatever) fine washers in the kitchen and some on my desk too.

Plastic case has a hole smashed into it only in the one pocket holding the 20 or so really fine small washers. ... most likely the exact ones that probably fitted the spill line banjo bolts too! :p

Went back outside and see the same trail of small washers out there too, and the broken piece of plastic that makes the base of the broken square. I epoxied it back up and used some packing tape to hold it there .. and all good.
Even tho mine wasn't broken up too badly all the washers were mixed up anyhow, so there must be just enough gap between lid and sectioned base, for all the washers to mix themselves up in an orgy of fun.

Took me about the same amount of time to dump them all on a clean surface and then sort them all out too.