99 606 injectors rebuilt about 5,000 ago. I pulled the cover of the the top of the injectors to inspect the plastic breather tubing that is leaking and I found this in the third injector well (full of diesel)



I swapped out some return line from another injector to see if it was the new return line that I replaced at the same time with the injectors. With engine running it looks like bubbles at the bottom of this injector so I pulled injector to see if I installed the seal wrong and it I think its correct (above pic) and I re-torqued but I still get bubbles at the bottom of the injector.

This is what I think is the wrong way to install the injector seal:

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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

I've never worked on a 606, but on the older seals, there is a small ring around the center hole. that ring faces the injector.
and if you removed, then re-torqued, the seals are dead, and must be either reset, or preferably replaced. they are a 1 time use only part.

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 560SL convertible
1987 190D 2.5-5SPEED!!!

1987 300TD
2005 Dodge Sprinter 2500 158"WB
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

the puddle of fuel must either come from the return lines, or the injector body. VERY unlikely to get a puddle from the heat shield (what you are calling a seal)
the most likely source is a chipped or nicked return line nipple, followed by a cracked nipple, then an injector body leaking... a LOT more air than fuel goes into the PC, so a heat shield leak would mostly blow air through a leak...

__________________
John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 560SL convertible
1987 190D 2.5-5SPEED!!!

1987 300TD
2005 Dodge Sprinter 2500 158"WB
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

This is the correct way.


The heat shields are single use.
Once you (make contact) begin tightening them, if you back-off they are junk.

Attempting to refresh-reuse "used heat shields" is begging for BURNT injector nozzles.


.

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1985 300SD
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Off topic:

Would it be dangerous to fire up an engine on used seals for say, 5 minutes to check timing?

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$60 OM617 Blank Exhaust Flanges
$110 OM606 Blank Exhaust Flanges
No merc at the moment

IMO; you risk BURNT injector nozzles if they are less than perfect (NEW).

Combustion temperature is an unforgiving fact.

Better safe than sorry.

.

These new heat shields or seal as the parts catalog calls them were replaced when injectors rebuilt. I only removed this one last night to see if it is the right way, which I now see that it was correct but now is junk. I ran the car at idle for maybe one minutes after I re-tourqued.

I will pick up a couple of new ones today along with some more new return line and reinstall, then see if it still leaks. If it does it sounds like the injector itself

__________________
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

Roger! $10 is a small price compared to new injectors

__________________
$60 OM617 Blank Exhaust Flanges
$110 OM606 Blank Exhaust Flanges
No merc at the moment

Anyone know what size that braided fuel line is? 7mm? I have some larger braided stuff but I want to be sure.

Also, If the injector body is bad and I buy a replacement I am thinking I will have to have it balaced to match the other 5 I just had balanced recently, correct?

__________________
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

If the body is leaking it probably wasn't wet-sanded properly.

-J

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1991 350SDL. 230,000 miles (new motor @ 150,000). Blown head gasket

Tesla Model 3. 205,000 miles. Been to 48 states!
Past: A fleet of VW TDIs.... including a V10,a Dieselgate Passat, and 2 ECOdiesels.
2014 Cadillac ELR
2013 Fiat 500E.

dauber: Just out of curiosity: besides the smell of diesel after a drive, did your engine shake at idle as a result?

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1995 E300 Diesel

... 7mm is HUGE!
I'd think it's more like 3mm or 2mm.
either way, the buy parts link at the top of the page, should list the size for ya!

__________________
John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 560SL convertible
1987 190D 2.5-5SPEED!!!

1987 300TD
2005 Dodge Sprinter 2500 158"WB
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

3.2 OD X 1.9 MM inner diameter.

Gasoline weed whacker pink fuel hose will work, any hardware or Home Depot - Lowes will carry it.

.

Thanks, I am not home and I did not bring a piece with me for comparison. I want to check it tonight after I pick up some new heat shields from the dealer.

Benedict:

This is the wife's car, but I did not smell diesel as it was not leaking down, just filling up the injector chamber I guess slowly. It does cold start rough at idle but only slightly and would level off quickly. I would not have found it if I did not take the cover off to inspect other things. If its the injector body I will be ordering one from here as the dealer wants $270. Figures, right before our trip to Yosemite on Friday, may be driving the gas hog.

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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

This is for a OM603 engine, but the same return line size.

What diameter fuel hose is used on the fuel injector return lines of an OM603?

If there is a VW repair or one of those VW high performance shops, they usually have the line. tell them it is for a Rabbit.

sometimes the guys behind the counter look at you and, Say what? but there will be one of them that were around when they were new, the pimple faced kid usually has no clue, as he wasn`t even born when the Rabbits were new.

Not sure if the VW Rabbits or jettas used the same heat shields or not.


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

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