Well, i've been noticing the smell of raw Diesel fuel the last week or two.


So i finally popped the hood to look, and i noticed that there is Diesel leaking from my number 4 injector. I can't quite tell if it is actually leaking from the black tubes that seem to daisy chain from one injector to the other, or if it is leaking from the threads where the injector mounts to the head.


I couldn't get a wrench on the injector itself to try to tighten it. I was able to remove and then tighten the metal fuel line that goes to the injector, but that didn't stop the problem.


What are these black hoses that go to the injectors? Are they vacuum lines? I'm assuming not, as they route back to a canister that says BOSCH on it that has banjo bolts connected to it, sort of like a brake caliper.


Looks like i'm going to have to remove the Intake Plenum or that runs across the valve cover and connects to the turbo, in order to get to this injector correct?

Can i start by replacing the black hoses that connect to the injector, or will i have to buy a complete new set of injectors?


Thanks.

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93 300 D 2.5 turbo

I'm not sure how to fix the problem, but I am interested in what you find out because the same thing is happening to injectors 1, 4, and 5 on my 1983 300TD. I also got a wrench on the top nut and it did not seem loose. I got a wrench on the surface just below the black lines, and it was not loose.

It's most likely those small hoses on the injectors (return lines). Get your self some and replace them. Just becareful on number 5 you don't lose the plug in the last return line.

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04 VW TDI Passat 80,000mi
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Replace the black cloth/rubber return lines, usually the problem.

If that doesn't fix it, clean the area with a good cleaner (simple green max works for me), and hose down the area (engine cold), start the engine and look for bubbles.

If between the injector and the lock-ring, it is probably the injector heat shield. If outside of the lock-ring, the prechamber to head seal is leaking, you will need to remove the injector and prechamber, ream the hole, install the correct washer for the new depth, and re-install everything.

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Gone to the dark side

- Jeff

What is the effect on the return lines if I have replaced the banjo bolt with a solid core bolt that does not return fuel to the fuel tank? The replacement bolt was part of a kit to run on wvo.

Thanks.

Just what you're seeing, the extra fuel will find a way out.

__________________

Gone to the dark side

- Jeff

Thanks guys.


Replaced the black line with thick walled vacuum line temporarily until i can get the proper plastic cloth covered line.

It seems to have fixed the problem. The old tube was hard as a rock and split.

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93 300 D 2.5 turbo