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Old 11-09-2013, 09:10 AM
Augenblick's Avatar
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Join Date: Feb 2013
Location: Rocket City USA
Posts: 27
Leaky Injectors

Near as I can tell the injectors are leaking on where the injector body comes together, is this something that can be solved simply by tightening the outside of the body, or do the need to be rebuilt. I'm hestitant to test it myself for fear of totally breaking them.

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Old 11-09-2013, 09:40 AM
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Join Date: Mar 2005
Location: SoCal
Posts: 660
Dont touch the injectors for now. Replace the fuel return lines first. I think thats where the leak is coming from. Your return lines are wet.
'85 300D Cal 280,000 miles
'07 C230 37,000 miles
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Old 11-09-2013, 09:55 AM
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Join Date: Sep 2010
Location: 2021 - The Great Florida Count-down
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X2 99% of the time it's the return lines. Rarely injectors leak at the halves. When they do, and excluding they somehow got lose, you generally cannot fix that.

As a caveat, I am not trying to generate a forum war of over the benefits of lapping or not lapping.

So, leaking halves is unlikely. 59 Ft Pds is the max. At this point, I would not remove your injectors if I were you. If you pull them, no more than 59 ft pounds. If you overtighten, and really overtighten, they will leak.

My .02 cents
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Old 11-09-2013, 10:05 AM
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Join Date: May 2007
Location: Out in the Boonies of Hot, Dry, Dusty, Windy Nevada
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X3 it is the Return Lines.

If you do remove the injectors, then you need to replace the metal Crush Washer under them. Some time also referred to as Heat Seals.

Nothing new, the lines are old. Be careful and do not knick the metal Nipples the fuel lines slip onto. DO NOT cut the hose. Pull it straight off with some Pliers. If a piece stays on because it broke pulling it, grab the side of the hose with the Pliers, sort of pinch it w/o touching the nipple and pull it off.

GREEZER is the go to man for Rebuilt Injectors.

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
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Old 11-09-2013, 10:16 AM
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Join Date: May 2003
Location: Northern, Virginia
Posts: 2,029
X4 on the return lines. No doubt about it; I've been there on each of my 4 diesels.

Peach Parts W124.128 User Group.

80 280SL
85 300SD
87 300TD
90 300TE 4Matic
90 300D 2.5 Turbo
92 300D 2.5 Turbo
92 300TE 4Matic
01 Saab 9-5 Wagon
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Old 11-09-2013, 11:37 AM
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Location: Long Beach,CA
Posts: 36,754
Where to buy fuel return hose VW RAbbit
Diesel Injector return lines, where to buy? - PeachParts Mercedes ShopForum
The Thread with the part numbers
fuel return line replacement part - PeachParts Mercedes ShopForum

Viton Injector return Hose part numbers
VITON Return line number - PeachParts Mercedes ShopForum

Some People have used Weed Wacker Fuel hose
This is a 3' Length of 1/8" Tygon Fuel Tubing from Dubro.
FEATURES: Yellow fuel tubing. For gasoline or diesel fuel only. Won't harden or crack, and remains flexible. 1/8" i.d. fuel tubing.
INCLUDES: One 3' Length of 1/8" Tygon Fuel Tubing
SPECS:Inside Diameter: 1/8"

NAPA sells the real Fuel Return Hose and some people have been using some sort of 1/8" Fuel Injection Hose they sell.

Vacuum Hose fits but will only last a week or so.

Every once and awhile someone has an Injector that leaks at the Base of the little Nipples where they are crimped over. If that happens get report that in this thread.

If the Injectors are leaking between the Nut and the Upper Body you can try re-tightening them. If that does not work the Injector needs to be pulled out of the Engine and taken apart in the inside precision surfaces lapped flat again.
The exception to the above is if the Injector Nut had developed a Hairline Crack. That would call for the Injector Nut to be replaced.
84 300D, 82 Volvo 244Gl Diesel
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Old 11-15-2013, 11:31 PM
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Join Date: Nov 2013
Location: Pittsburgh PA
Posts: 343
x5 on injector lines. i had the same problem on my newly purchased 82 300d. ordered the weed wacker fuel line and replaced them all. the first one is a little difficult to install..i used long tipped needle nose pliers.

dry as a bone now

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