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#1
06-30-2010, 03:10 AM
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what other injectors fit 616/240D?
I have a 77 240D, and I can see that a little bit of diesel is seeping out of one of the injectors a little bit, so I figure I should rebuild them soon. I've put new nozzles in VW injectors in the past, so I was thinking of finding a used set of injectors, buying new nozzles and cleaning them up and lapping them and then swapping them out for the ones I have.
What other models/years can I get a set of injectors from to rebuild?
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1976 Mercedes 240D, unknown mileage 1977 Mercedes 240D, 225k 1992 Dodge/Cummins 4WD, 284k 1990 Subaru Legacy wagon, 330k 1991 Subaru Legacy wagon, 225k 
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#2
06-30-2010, 05:49 AM
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Any na 123 diesel. The turbo injectors are different.
I would check your return hoses. They will seep when they get old but the injectors hardly ever leak. 
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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual. [SIGPIC]..I also have a 427 Cobra replica with an aluminum chassis.
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#3
06-30-2010, 07:47 AM
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^ Agreed, with all of the above. Replace the jumper lines first, as it's rare for an injector to start leaking.
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83 SD 84 CD
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#4
06-30-2010, 12:29 PM
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The return lines look new, but I'll double check them anyway. Thanks!
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1976 Mercedes 240D, unknown mileage 1977 Mercedes 240D, 225k 1992 Dodge/Cummins 4WD, 284k 1990 Subaru Legacy wagon, 330k 1991 Subaru Legacy wagon, 225k
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#5
06-30-2010, 12:47 PM
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Heat shields?
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'85 300TD "Puff The Magic Wagon" - Rolling Resto '19 Mazda CX-9 Signature - Wife's sled '21 Morgan 3-Wheeler P101 Edition '95 E300d - SOLD '84 300TD "Brown Betty" - Miss this one '81 240D "China Baby" - Farm grocery getter
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#6
06-30-2010, 01:29 PM
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I'm not sure what the heat shields would have to do with the kind of leak that I think I have. It appears to be seeping from the seam where the two halves of the injector body go together.
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1976 Mercedes 240D, unknown mileage 1977 Mercedes 240D, 225k 1992 Dodge/Cummins 4WD, 284k 1990 Subaru Legacy wagon, 330k 1991 Subaru Legacy wagon, 225k
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#7
06-30-2010, 02:33 PM
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Yeah, those lines can look fine on the outside, I've replaced mine that looked that way only to find multiple cracks radially.
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83 SD 84 CD
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#8
06-30-2010, 11:51 PM
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The VW Rabbit Injectors are rebuilt the same way as the Mercedes ones. Different Nozzles and Pop/Opening Pressures.
Do you have a Nozzle/Pop Tester? Sometimes pulling the Injector and doing the Torqe on the Injector Nut cures the leak if it is actually leaking as said; but not often.
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84 300D, 82 Volvo 244Gl Diesel Last edited by Diesel911; 07-01-2010 at 12:03 AM.
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