FLK-011 Fitting Instructions - Defender 90 200Tdi (1990-1994) Fuel Line Kit

Pioneer 4x4 · Fitting InstructionsFLK-011

Defender 90 200Tdi 1990-1994

On-page fitting instructions for the three-line Pioneer 4x4 fuel line kit for the 200Tdi Defender 90 with sedimenter. Check the vehicle fitment and compare all three lines with the originals before removing anything.

Fitment

Model	Engine	Years	Fuel system	SKU
Defender 90 (L315)	200Tdi, 2.5 L 4-cylinder diesel	1990-1994	With sedimenter	FLK-011

Read first

Before you start — fuel is flammable

Work in a well-ventilated area away from any source of ignition. Offer the new lines up to the vehicle and check them against the originals for length before removing anything. Drain the system, catch any spillage and keep fuel off the paintwork.

FLK-011 contains three fuel lines only. Replacement nuts and olives are not supplied; obtain compatible new fittings before starting. Route each line without kinks or twists, secure it in its original clips and rubber bushes, and keep it clear of heat, sharp edges and moving parts. Prime and bleed the system using the vehicle manufacturer's procedure, then check every disturbed connection for leaks before driving. If you are not confident, have the kit fitted by a competent garage.

Before you fit

Remove the original nuts and olives

On the hardline tails at the fuel tank, sedimenter, lift pump and fuel return you will find the original nuts and olives that took the OEM fuel lines. The new Pioneer 4x4 fittings use a different thread, so the original nuts and olives must come off.

FLK-011 contains three fuel lines only; replacement nuts and olives are not supplied. Obtain compatible new nuts and olives for the new line fittings. You can carefully cut the original olive to free the nut, but this risks damaging the hardline tail, so fitting new parts is recommended. Do not force or reuse the original nuts and olives.