602 turbo motor leak at return hoses - PeachParts Mercedes-Benz Forum

mattchaney · #1 11-10-2009, 09:17 AM

How's it going everybody? So listen to the conundrum that I'm in and tell me what you think.

Backstory; I bought a 1990 124 with a 2.5 turbo motor about a month ago and have been working the bugs out since. At first I had no boost so I did GSXR's wastegate swap and it worked like a charm. Shortly after which I lost compression on cyl 2 due to a precombustion chamber splined nut backing itself loose. Upon checking the other 4 cyl's I found bubbles around those chambers. Ended up taking off the intake (to clean and whatnot) and removing all prechambers to clean and install with with shims to help with sealing (worked great!). While the intake was off I turned up the full load screw (as outlined in another great GSXR thread), deleted the egr, and replaced my injector nozzles with Monark ones (and balanced my injector opening pressures).

Problem; I got the car together and running last night after work and it was idling much better than it had been. Also, the fuel slap noise that I had before was gone and so were my bubbles. Sounds great, right? Only problem being that the return line on my # 5 injector is PUKING fuel. I did use new mb braided fuel return line before anybody asks.

The #5 injector is the one that has the "dead end" plug on it and I wonder if that could have something to do with it. At first the leak was from the dead end plug so I swapped the plug to the other bleed port and put the "jumper hose" where the leak had been. The leak stayed on the port that had been leaking before (was leaking at dead end hose, now leaking at jumper hose).

I haven't really had time to properly suffer through this yet and won't until after work today. I was just sorta wondering if anyone else has had a similar problem or has any good ideas before I try and work this out myself

Thanks for reading
Matt

sasquatchgeoff · #2 11-10-2009, 10:29 AM

Probably a cracked injector return hose barb. There are a zillion threads on that issue. Seems the wrong 27mm deep-well socket (i.e. Harbor Freight, etc) will bind against the barbs during removal/torquing. Happened to me. Only solution was injector body replacement - luckily my injector shop had some laying around. Only problem is the injectors had to come back out and be rebalanced.

mattchaney · #3 11-10-2009, 10:46 AM

I'll betcha your right! I did use a junky socket while installing the injector and I remember coming at it sorta crooked. Oh well, lesson in life I guess! I appreciate the help
-m