Hello, I was hoping my first post here would be under better circumstances but here goes. I recently bought a 1987 300SDL and am very happy with the purchase. Today I managed to hit an injector fuel return loop between injector #4 and #5 with a flash light breaking it to pieces. I believe it was the original braided fabric line and it was very hard and brittle. My problem is that I can't seem to get the hose off of the metal stem on top of the injector. I have tried to pry and scrap the piece of rubber off but I'm afraid of breaking/bending the stem.
Is there anything I can do to make if come off or dissolve it away? It is cold in Chicago today (~30F) and I know that doesn't make it any easier but I'm not sure how to heat the injectors up safely. Does anyone have any ideas that could help me out. Thanks.

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1987 300SDL-268k mi

Just gently scrap/cut it off with a knife or single edge razor blade. A small wire brush might also work.
Have you located a source to buy the new fuel injector return line?
Vacuum hose from the auto parts store will not last very long and gets eaten up.
This hose can be had at the MB dealer but is expensive. The Volkswagen dealers also sell the hose as the older VW rabbit diesels use the same injector return hose.

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84 300D, 82 Volvo 244Gl Diesel

I've removed the hoses by using an industrial heat blower which looks like a heavy duty high output hair drier. You can always buy the hose from our sponsor in the "buy parts" tab. The vacuum hose might be OK as a temp fix until you get the hose you need. If the one piece is brittle, you need to replace the rest.

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DJ


84 300D Turbodiesel 190K with 4 speed manual sold in 03/2012

Those return lines come off hard sometimes. I use a needle nose pliers. I slit the line vertically with a single edge razor. Be careful not to scartch barbs on the fitting or it can leak.

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

If the hose is expensive at your dealer, find another. The last time I bought return line at a dealer, $11 bought enough for a 617.

Thanks for the good info. I will borrow my friends heat gun tomorrow and see if that will make it easier. I am trying to keep it clean without creating little bits of rubber that could clog the injector or lines.
I have already ordered 4' of 1/8 ID Viton hose for $13 from a local supply house. That should take care of the return lines. I had hoped to replace all of the fuel lines in the spring when I start running some biodiesel but now I don't get wait.

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1987 300SDL-268k mi