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  #1  
Old 04-22-2010, 11:17 AM
KCM KCM is offline
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OM621 Injector Return Line Fitting Leak

Hi all,

On the OM621 diesel engine, there are banjo-like return line fittings that fit on top of the injector and are held down with a nut at the center. There is an inner and out sealing ring, with a channel in the center for the fuel to return from the injector. Every time I take one of these off and reinstall I get a leak around the outside circumference. I suspect over time they warp as the nut clamps at the center but not well around the outside.

Anyone have any tricks to get these to seal or ways to true up the surface so they seat better? Or a cheap source for new replacements?

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Old 04-22-2010, 03:28 PM
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Get some 500 grit emery paper on top of a extremely flat surface. Put some light Oil or Water on the paper and sand them to true them up.
The water or Oil will help keep the paper clogging quickly.

Look for nicks or high spots on top of the Injector where the Banjo seats.
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Old 04-22-2010, 11:22 PM
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Even with this minor inconvenience, this system of overflow return is so much superior to what MB went to on the 123's. The banjo bolt style was also used on the W115 and allowed us to drive the 220D for 20 years with no thought to rubber return lines!!!
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Old 05-12-2010, 11:32 AM
KCM KCM is offline
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Just an update. Tried the trick with silicone carbide sand paper and oil. Used 800 grit, then finished with 1000 grit, using a flat piece of steel as the backing. My first try was unsuccessful, and it leaked worse then ever. Took it off again, lightly sanded, and cleaned up the injector contact surface real well. Worked like a charm the second time. Must of had a piece of dirt under the fitting the first time. Thanks very much for your help.

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