Quote:
Originally Posted by PradoTDI
Turns out the little rubber cap on the #5 injector return nipple was cracked, so that was probably part of the air leak. I temporarily replaced it with a vacuum cap since none of the parts stores locally even knew what I was trying to get. Did some searching here at Pelican Parts but came up empty handed as well.
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You don't need it. Instead of the solid rubber cap some have a simple say 1 inch section of the return hose with a metal plug in one end. There is a special made metal plug that looks like a BB with a short stem on it.
Most people get something like a fine threaded machine screw that is slightly larger than the return line and coat the threads with some gasket sealant and shove it in. And they last longer compared to the solid rubber cap.
Places that sell the return hose that might be local.
A Mercedes dealer.
VW dealer because the same return hose was used on VW rabbits and likely on some smog systems in newer cars.
Volvo dealers because the Volvo diesels use to use the same type of Injector bodies. Sold in 1-meter lengths. The same hose may also be used on gasoline models.
NAPA (national auto parts)
Regular automotive vacuum line will work but might only last 2 weeks. Well enough for an on the road fix to get you home.
I have used a section of silicon vacuum hose between injectors, and it worked and sealed fine but within a year it got rock hard. It did not leak but lost all elasticity and I could not pull it off. I had to cut it off.
Somewhere there is a thread on the injector return lines and where to get them and part numbers of the VW return line.