Ugh.

Reason #236 for not getting pissed off while driving.

Dropped down to 3rd gear and revved too high for too long and blew the plug out of the fuel return line end... Sucks.

At least I have another at the house and a coworker is going to run me over to get it at lunch. Parking lot smells nice now...

__________________
'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

On second thought, shouldn't the return be a rather low-pressure system?

__________________
'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

It is.....fair amount of volume...but low pressure. Your return lines aren't petrified....are they? That plug is barbed and doesn't even need a clamp to stay in.

__________________
Proud owner of ....
1971 280SE W108
1979 300SD W116
1983 300D W123
1975 Ironhead Sportster chopper
1987 GMC 3/4 ton 4X4 Diesel
1989 Honda Civic (Heavily modified)
---------------------
Section 609 MVAC Certified
---------------------
"He who fights with monsters might take care lest he thereby become a monster. And if you gaze for long into an abyss, the abyss gazes also into you." - Friedrich Nietzsche

No, lines were changed about 2k miles ago. I did redo the plug myself though. And the plug was straight-sided IIRC. The injector stubs are barbed, but I remember the plug being smooth.

Anyhow, Carquest had some available pre-made and I don't feel like digging around the garage at lunch. So I'm going to go pick up a couple of them.

__________________
'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

Guess there are different plugs out there then. The ones I have are barbed. If the next is smooth....find a clamp or push it far enough in you can jam some glue to help stake it in place.

__________________
Proud owner of ....
1971 280SE W108
1979 300SD W116
1983 300D W123
1975 Ironhead Sportster chopper
1987 GMC 3/4 ton 4X4 Diesel
1989 Honda Civic (Heavily modified)
---------------------
Section 609 MVAC Certified
---------------------
"He who fights with monsters might take care lest he thereby become a monster. And if you gaze for long into an abyss, the abyss gazes also into you." - Friedrich Nietzsche

That would explain your problem.

That is what golf tees are made for = emergency hose plugs..







.

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1985 300SD
1983 300D
1984 190D
2003 Volvo V70
2002 Honda Civic

https://www.boldegoist.com/

A small screw from the hardware store should work just fine.

__________________
1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

Maybe, but it was in there pretty good and I assembled the new end the same way.

I attribute the blow to more my stupidity of revving the engine too high...

__________________
'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

That won't cause it to pop. You never get enough pressure in those lines to do it. Its unrestricted flow back to the tank. And I know a guy with documented proof (video) that has had his to well past the stock governed speed (yes it was tweaked) and that was way beyond what you could have rev'd it to. His never popped out......mine has been to the stock governed limits a few times and I've never popped one. And a lot of people here have really abused theirs and they never popped it.

__________________
Proud owner of ....
1971 280SE W108
1979 300SD W116
1983 300D W123
1975 Ironhead Sportster chopper
1987 GMC 3/4 ton 4X4 Diesel
1989 Honda Civic (Heavily modified)
---------------------
Section 609 MVAC Certified
---------------------
"He who fights with monsters might take care lest he thereby become a monster. And if you gaze for long into an abyss, the abyss gazes also into you." - Friedrich Nietzsche

The proper plug is shaped just like an injector nipple, minus the hole. The higher the pressure, the tighter it holds.

Maybe the return system is restricted somewhere.

__________________
1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

It's worth noting that the return lines did not blow off any of the other 10 (presumably proper) connections.

the hose end may be damaged, or the return hose material may be defective.

This is part of why I keep three brands of return hose in my garage + carry one meter in each car.

Looking at the piece of hose that I had made the end from, the braiding had unraveled from the plug end... So that would explain how the rubber expanded, allowing the plug to escape.

Blowing a fuel leak just felt like a blood vessel that the jerk was making boil in my neck...

__________________
'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