diesel injector return nipple leak

[blackbean]

I have leaks at the base of couple diesel injector return nipples on my 1993 300D. Anyone have any recommendations to salvage the tops of these injectors? Someone had recommended silver solder to me, but I thought there might be more affordable solution. Can JB weld handle the temperatures on top of one of these injectors?
Thanks,
-Mark

[Diesel911]

JB Weld can handle the temp but I do not know if it would work.

One of the Members cut the Nipple off and Welded over the Hole and moved that Injector to the very end where one of the Nipples would have a Plug on it.

Home Depot has some Silver Bearing solder that has about a 410-450 degree Melting point. This is well within the temp range of a Propane or even a little butane torch (in fact some ovens go up to 450 degrees).
The problem is getting the Silver Solder to wick into the space you want it to go into.

[Biodiesel300TD]

Are you sure it's not just the injector return hose leaking?

[blackbean]

Biodiesel, it is base of nipples that is leaking. I tweaked them both with a not-deep-enough socket; hopefully this will warn someone against trying to save money on using the wrong socket. Still not sure where to get a deep enough deep socket for injectors. I'll try peachparts and see what they have.

Diesel911, I have heard about the silver solder you mention which is mostly tin and sometimes a little copper. I have a soldering iron that can melt this. I should be able use the corresponding flux to get it to flow into the correct place- around the base of nipple. I wasn't sure if this would be high enough temp for the injector and am glad to hear you think it might work. I'll give it a shot.

thanks,
-Mark

[ah-kay]

If the base of the nipple is leaking then you 'probably' cracked the nipple. I would think it is unlikely even though you were using a not-deep-enough socket. You may have bent it but not cracked it. if you did crack it then JB weld would fix it but clean/degrease the area well first.

I suspect it is leaking from the barb shape part of the nipple. You can try this - wrap the nipple with a bit of teflon tape and and shove the return line in. Use new return line which is more supple.

Good luck.

[wilburtual]

i just got a deep 27mm socket at autoz*ne that fit and worked great, i little pricey at 8.99 for one socket... but i didint have the time to go to harbor freight. HF sockets are usually onsale for .99 each! i know lots of folks rag on their quality, but the only time ive ever used my deep 27mm socket was to pull 1 injector, so i wish i would have spent .99 instead of 8.99.

ive never used JB weld on injectors, but have on lots of other things, and it always seems to work and hold... i'd just make sure if you solder/wled something on there, to make sure there is still enough room to properly seat the return lines- which i would also recommend getting brand new ones, ive never had reused ones sit well and not leak.. i replaced them once and one still leaked, til i found a little piece of gunk at the bottom of the nipple which was making the return line not fully plug on there, and thus still a little leak

[Diesel911]

Originally Posted by blackbean

Biodiesel, it is base of nipples that is leaking. I tweaked them both with a not-deep-enough socket; hopefully this will warn someone against trying to save money on using the wrong socket. Still not sure where to get a deep enough deep socket for injectors. I'll try peachparts and see what they have.

Diesel911, I have heard about the silver solder you mention which is mostly tin and sometimes a little copper. I have a soldering iron that can melt this. I should be able use the corresponding flux to get it to flow into the correct place- around the base of nipple. I wasn't sure if this would be high enough temp for the injector and am glad to hear you think it might work. I'll give it a shot.

thanks,
-Mark

A Soldering Iron for Electrical type work will not get hot enoungh to melt the Silver Bearing Solder. Alghough it is possible that lead type solder (melts some where in the 200-300 degree range) might also work. (I do not know if Diesel Fuel will eat up Lead or not; it will eat up Zinc.)

You can look on Home Depot's Website and see what the have.

[charmalu]

How about a Mig welder, just zap the hole after it is well degreased.

Another option is pull one from the Junk Yard.

Charlie

[Dieselboy740]

I had one do the same thing. I ended up replacing the injector with one from another engine. They (return nipple) seemed to be pressed in.

[Diesel911]

The Return Nipples are pressed in and then a circular Crimp is applied arround the Nipple on the body of the Injector.

If he swaps out the upper Injector Body there is a good chance it will change the opening pressure of the Injector.