I had some Questions about replacing my Injectors, I know I will need new Washers to go under the injectors, and I have read and have been told how to properly bleed the air out of the system. When I have the injectors out, should I replace the Injector Over flow line, the Cloth covered line that goes form injector to injector? I dont know if there is anything wrong with the current ones, but I assume that they get changed with the injectors, correct?

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hum.....
1987 300TD 311,000M Stolen. Presumed destroyed

Aqua,
Buy a yard of the injector return hose. Its not that expensive. You will most likely break some of the lines getting them off. I just use a box cutter to get them off the injectors. The hose tends to get hot on the injectors and goes hard & cracks in time. When you have the injectors back in, just cut new flexible hoses to suit. That way you should have no leaks of fuel.

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Grumpy Old Diesel Owners Club group

I no longer question authority, I annoy authority. More effect, less effort....

1967 230-6 auto parts car. rust bucket.
1980 300D now parts car 800k miles
1984 300D 500k miles
1987 250td 160k miles English import
2001 jeep turbo diesel 130k miles
1998 jeep tdi ~ followed me home. Needs a turbo.
1968 Ford F750 truck. 6-354 diesel conversion.
Other toys ~J.D.,Cat & GM ~ mainly earth moving

Yeah, might as well replace those lines. AFAIK that engine uses the same injectors as a 617.

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83 SD

84 CD

If you use any sort of cutter be sure not to nick the little nipples that the Hose hooks to in the Injectors as it can cause a leak.
Since you are removing the Injectors you could just cut the Hoses close to but not onto the nipples and remove the Hose ends after you get the Injectors out of the Engine.

After about 4-5 years (or sooner?) of use the Fuel Return Hoses/Lines looses elasticity and when you remove them it often causes them to leak if you put the back on; even if you cut them shorter.

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84 300D, 82 Volvo 244Gl Diesel

Thats what I thought... This is an old Tan colored Cloth covered Tube, I dont know if they are original which is doubtful but I figured I would have to replace them

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hum.....
1987 300TD 311,000M Stolen. Presumed destroyed

I use a pair of diagonal cutters to sort of squeeze the return line of its nipple that way you don't do any damage to the nipple that could contribute to a leak in the future. I remove all the return hose off the nipples before removing the injector, depending on the 27 mm deep socket you use to remove the injectors some will have so little clearance up inside of the socket if you leave the return line just on the nipple it will interfere with getting the socket over the injector. Then if when your removing the injector you let the socket get canted over to one side when your applying force to remove it you can inadvertently bend a return nipple. Some of these injectors can take quite some torque to break them free, I usually use an 18" breaker bar that way you can more easily control what force your putting on things and keep the tool straight and square while you're doing that.

Get yourself some Viton hose and you can forget having to replace the lines when they start leaking, because Viton will last a decade or more as it doesn't lose its elasticity or get rotten.

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'95 E320 Wagon my favorite road car. '99 E300D wolf in sheeps body, '87 300D Sportline suspension, '79 300TD w/ 617.952 engine at 367,750 and counting!

Before I knew about Viton Hose I bought what must be at least a total 30 feet of return line hose when I saw it at a good price on eBay (several purchases).
My Volvo also uses the same Hose on the Injectors and I have also used it as Vacuum Hose and Window washer Hose.

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84 300D, 82 Volvo 244Gl Diesel