So I've been trying to get my 617 running without leaking fuel everywhere for a little while now.

I replaced the injector with an older one from the old engine I had swapped out earlier. The injector hadn't been in a particularly clean storage area, so I rinsed it out as best i could with some mostly methonal diesel additive before Installing it. The supply line to this injector was still leaking at the IP so I replaced it with the older one. Still leaking so I replaced the delivery valve. After this I thought I was making progress because it didn't appear to be leaking any more when I got it started up. I washed the outside of the engine and IP and left it to dry so I could start it up later and see if and where it was leaking.

I started it up to show a friend of mine that night and heard a really loud crack when I was revving int manually with the linkage. furter inspection revealed a crack in the injector body starting at the top of the 27mm hex and heading down. Needless to say it was now leaking again.

I still have some more injectors from the old engine, but i'm not particularly excited about swapping another one on there now. What do you guys think made the other one crack? Clogged tip? What should I do?

If the outside was rusty the inside may have been frozen.

Pop testing and balancing would seem most appropriate in choosing a new inj.

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Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)

Fatigue. They are metal, like other metals, and subject to fatigue. There are sections in it that are somewhat thin. If the nozzle were to be clogged the fuel should be going into the return line.

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1987 300D (230,000 mi on a #14 head-watching the temp gauge and keeping the ghost in the machine)
Raleigh NC - Home of deep fried sushi!