Well I picked up some new heat shields from the dealer, they wanted $4.89/each and had 4, but I talked them down to $2.12 each.

I tired to get some return line but had no luck at two separate hardware stores so re-arranged the ones I bought 6 months ago and put it together. No leaking or bubbles like I saw last night after a long drive and idling. So, it was either not torqued right or the head shield not seated properly or a return line-I have no idea.
Or maybe its a slow leak from the injector body and it will return. I am going to keep the cover off for a few months so I can keep an eye on it and wish for the best.

Charlie- I had the same idea in mind as I have owned VW's and had luck getting braided line at local shop. Didn't know about the Rabbit as the same size, so good to know.

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1999 E300 TD 190,000
1996 Passat TDI 225,000-sold
1996 E300 120,000-sold
1998 Jetta TDI 186,000 -sold
1983 Chev Suburban C20 6.2-sold

Well Iam not real sure on the Rabbit either but there sure were a lot of them around here at one time. assumed it would fit one, wasn`t into the VW of that erra. had a 67 and 69 Bug.

The NAPA store across from the VW shop also sells the braded line.

Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

Well I guess I over fixed it buy pulling the injector off. It is definitely just a bad return line or two. I checked it tonight and now #4 had fuel in it and #3 was dry after I switched around the return lines yesterday. I could not find any yesterday and I was not going to pay the dealer as that is where I bought this stuff 6 months ago.
I put some silcone tubing I had on hand from my VW that was the same size until I can source some good line. And all is good.

WOW is this car quiet now! I have owned it a few years and a '96 before this one, but never heard a 606 this quiet! I guess that calls for a beer as I must have fixed all the air leaks in this car.

__________________
1999 E300 TD 190,000
1996 Passat TDI 225,000-sold
1996 E300 120,000-sold
1998 Jetta TDI 186,000 -sold
1983 Chev Suburban C20 6.2-sold

VW 1.5, 1.6 and 1.9 IDI diesel injector heat shields are exactly the same as MB ones, just cheaper.

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2012 BMW X5 (Beef + Granite suspension model)

1995 E300D - The original humming machine (consumed by Flood 2017)
2000 E320 - The evolution (consumed by flood 2017)

Here is a picture of a new heat shield, and one that has been used.



Thanks to GSXR.

Charlie

__________________
there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

It appears I spoke to soon, I checked it yesterday and diesel is in #3 again, about a 1/4 full. I ordered a injector from Peach and will replace.

__________________
1999 E300 TD 190,000
1996 Passat TDI 225,000-sold
1996 E300 120,000-sold
1998 Jetta TDI 186,000 -sold
1983 Chev Suburban C20 6.2-sold