Terminal Injector Return Line?
 

Hi Everyone,

The stopper on the final injector (#5 in this case) has cracked and sprung a leak. I am looking for suggestions for a stop gap or permanent repair. I am about 100 miles from home and can't seem to actually find the part number to have the part store look it up. Any suggestions would be great.

Thanks.

A piece of hose the correct size with a bolt in the end and a pipe clamp just to make sure it doesn't come off should work. Are you near a hardware or auto parts store? Is it just the hose that has cracked? If so you need a new piece of fuel line and you can reuse the stopper.

Thanks for the idea. Didn't know if I could get away with just sticking a screw in there. Now to find some fuel line, I am sure I can at least get some small engine fuel line for a short term fix.

I used a Fine threaded Screw with Silicon Sealant coating the threads. Wipe off the excess Sealant from the Exteriorn

Silicone sealant nothing that is in contact with diesel, it turns to gel.

It does that with Gasoline. I have not see that issue with Diesel Fuel and as I said it is how I did mine; and no issues.

But, I suppose that nasty Brown none hardening Permatex would also work as a sealant.

Now that I think about it I used the Ultra type Silicon Sealant on the Cover of the Fuel Injection Pump on my Volvo; because I managed to pinch and take a bite or of the New Gasket I had to reuse the Old Gasket. And, that has been at least 3 years ago I did that.

The Pump Housing pressure can go as high as 30 something PSI.

When you get home, best replace all the return lines. If one bit is bad, they will all be bad.
I have a small piece (1/4") of thick fence wire jammed in a short length of return line as my stop. Never had a problem with it.
All my return lines are about 3" longer than they need to be. If one cracks on the end, I just shorten it an inch or so. The heat of the injectors appears to make the return line go hard & crack.

A 16 penny nail(no threads to silicone) makes a good plug for the last injector line. Any fuel line of the correct size (I think it's 1/4" or 3/16") should work to get you home. You will eventually want to replace them all with viton fuel line if you are going to be running much "biosudd's" threw them.

It's no fun losing an injector return line. Especially if it takes you a little while to realize it.

I keep a 4ft piece of injector hose in a freezer bag along with a razor blade knife, pair of needle nose pliers and dykes in the trunk. (Boot)
The little end piece can be removed and put into a new short piece of hose. In a emergency anything can be used to plug the hole.

I use the pliers to pull off the old hose, and it usually tears off and leaves a piece on the Injector Nipple. do not use a knife to cut it off the Nipple, it could knick it and cause a leak. I use a pair of pliers to grip the edge of the rubber (sort of pinch the side) and pull it off. there is always that elusive piece that stays on the back side, this where the needle nose come in handy to dig it out.

Fence wire is a good idea Layback, always keep a pair of fence pliers in the trunk incase you break down near a field of Cows, then just cut off a chunk of fence. :D JK JK.


Charlie

Alternate line & plug
 

In a pinch I once had trouble finding return line sized hose from the box stores i.e. Autozone etc.

But if there is a motor cycle shop nearby you can grab some fuel line from them that will fit snug on the injector and plug the other end with what ever you choose until you get the real stuff.