200 Tdi Cold Weather Issue or Something More Sinister?

Snagger

Explorer
Diesel filters are much finer than petrol as elderly petrol engines use carbs, so only the big bits of crud would block a jet. Injectors, on the other hand, will block much more easily. You also need to allow for the fact that diesel is that much more viscous, so just a touch of gelling might block a filter, especially with any water contamination. As stated, make sure that the filter is positioned after the lift pump, otherwise you'll probably end up sucking air into the system and straining the lift pump diaphragm too.

You can get heater units that fit between the filter and the housing. I put one on my 200Tdi powered 109 just to prevent any chance of the same problem (we had -19oC here last winter and have had -12 last week). This was standard fit on Arctic-spec vehicles, and is very simple to install. It uses a ignition-switched feed from the fuse box through a thermostatic switch, so will cut in automatically whenever needed and be isolated when the engine ignition is off. I measured its draw at 10A.
 

gm13

Adventurer
I do plan on picking up a heater for the Racor 230R, they make a 200watt unit. Sedimentor arrived today, got it installed along with new 5/16" fuel lines from heater T to lift pump and a 2 micron filter for the above. Need to bleed it further but started and idled smoothly. I only had to go to 10 places to find the fittings I needed, life in the hinterland.. The Delphi unit does use a standard 1/4" flare fitting.
 

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