I took the plastic cover off the top of my engine today (1995 E300D OM606) and the cavity for the injector closest to the firewall is full to the rim with diesel fuel. The line going into the top of the injector is snug. What could cause this leak and how would I fix it?

Thanks in advance...

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I can't tell if the return line is leaking or if it has just soaked up leaking fuel.

Can you tell me how the return line is attached? This car is pretty new to me and I don't want to just yank one off from one of the other injectors...

It's just pushed onto a barbed fitting on the injector. Just replace all of it while you have the cover off. It should cost less than $20 for the hose at the dealer. You buy a length and cut it to fit.

In your first image, note the short hose with the metal plug for the last injector. Replace that short line too, and reuse your old plug.

That is a return line failure. On these cars it is a particular pain in the rear to change them because the injectors in those wells. Pulling them off with needle nosed pliers and shoving them back on with the same is about the only way to do it. You need some long needle noses though. Good luck, Jim

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Own:
1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles

Owned:
1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)

Thanks very much guys.

I just did this. Every line just cracked off at the top of the barb. It was a real pain in the ass to get the rest of the hose off of all 12 barbs, it was brittle but also rock hard. I used an exacto knife and went through about 12 blades.

I replaced them with viton lines.

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If your return hoses are anything like mine were, they'll probably be hard and brittle at the barb of the inkector and they will break as you try to pull them out. Like JimSmith said, you'll need a set of good needlenose pliers and you'll need lots of patience to pull the hard, broken pieces out.

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1995 E300 Diesel
2002 GMC Duramax CC LB 4X4

Can I leave the plastic top cover off the engine, reattach the throttle cables and intake pipe and drive it that way for a week or two?

Since your half way there, I would also pull off the Intake Manifold and replace all the plastic fuel lines...If they are a few years old, they will start leaking on you, and its rather hard to see where the leak is comming from.

Sure.

The new retrun line sold at the dealer is grayish tan in color rather than black. In fact, mine was that color from the factory. Gives you an idea how old yours probably are.

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Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)