I changed the return lines on my 240D and though that's not super difficult, it can be knuckle-busting.

I can use pliers to pull off the return lines if I can't wiggle them off, but sometimes the ends tear off.

1. I used a small pry bar of the type used to pull out upholstery staples and/or trim panel p-lugs. It's small enough and sharp enough to cut the neoprene without bending the metal return line tubes.

2. Try as I might, getting the #3 return line at the rear of the injector is tough. I slit a 4" piece of neoprene fuel line, then wrapped it around the return line to stiffen it as I wiggled it on. Worked like a charm!
Then just opening the neoprene line at the split and it separates from the fuel line.

just thought I would pass that along.

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Strelnik
Invest in America: Buy a Congressman!

1950 170SD
1951 Citroen 11BN
1953 Citroen 11BNF limo
1953 220a project
1959 180D
1960 190D
1960 Borgward Isabella TS 2dr
1983 240D daily driver
1983 380SL
1990 350SDL daily driver alt
3 x Citroen DS21M, down from 5
3 x Citroen 2CV, down from 6

"I slit a 4" piece of neoprene fuel line"

Was that supposed to be: I slit a 4" piece of neoprene Fuel Return Line?
Or was it some other Fuel Line?

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84 300D, 82 Volvo 244Gl Diesel

Dip the ends in diesel first, it'll go on easily by hand. On broken stubs of old return line, I use needle nose pliers to pinch the sides of the hose. It stretches and loosens the hose without nicking the barb and comes right off.

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

X2 on this trick, works great.

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

I usually just use a razor or sharp pocket knife to split the hose at the barb connection. be careful not to gouge the return barb.

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1991 F250 super-cab 7.3 IDI. (rebuilt by me) Banks Sidewinder turbo, hydroboost brakes, new IP and injectors.
2003 S430 - 107K
1983 300SD - Tanoshii - mostly restored ~400K+.
1983 300SD - Good interior. Engine finally tamed ~250K.
Monark Nozzle Install Video - http://tinyurl.com/ptd2tge

X2 I learned this trick on this forum. First time, I changed them I had a heck of a mess.

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daw_two
Germantown, TN

Links:
Sold last car --- 05/2012 1984 300D Light Ivory, Red interior
Cluster Needles Paint
New Old Stock (NOS) parts

Past:
3/2008 1986 300SDL "Coda"
04/2010 1965 190D(c) "Ben"
& many more