OK, I give... how the heck does the "heater feed" fit back into the fitting on the head on a 602? I put a new o-ring on the line, and it slips into to fitting -- a nice, tight fit -- but it will NOT go in far enough for the original clip to hold it in place. It's not going anywhere, but it needs to go another 1/8" or so for the clip to slip into the recess that it I'm assuming it needs to fit into. I have tried and tried to pry it into place, but it's hitting something and just won't budge any further. I can feel it hitting (feels like metal on metal), and there's just no more give. Am I nuts, or is this thing this much of a PITA for everyone? I gave up after a couple of hours dinking with it and am just going to hope it stays put and is water-tight. In my frustration I broke the clip anyway, and will need to order a new one. Grrrrr...

Thanks all!

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1992 300D 2.5T
1980 Euro 300D (sadly, sold)
1998 Jetta TDI, 132K "Rudy"
1974 Triumph TR6
1999 Saab 9-5 wagon (wife's)

from experience:

when putting the head onto the block, this line must go in at the same time. It happens with a kind of 'clunk' as the rubber spins and deforms. I remember it being mostly effortless.

--Remove the mounting screw from the oil filter canister and the next mounting hardware you can reach. Take the line back out, spry it with silicone or some kind of light lubricant (even soap is good). Then try the process again and mount it back up.

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I would definitely replace the clip. jt20 is right - its best to be pushed in while placing head on block having lubed the gasket with silicone, spit, or soap. They are a PITA and generally worthless for climates that hardly ever dip below 32 F. The major issue is the oil filter canister being in the way.

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327K on 1986 W201, 602.911, 722.414 2.5 190D ("The Red Baron")
139K on 1993 W124, 104.942, 722.433 2.8 300E ("Queen")

http://farm5.static.flickr.com/4081/...0bb92d3c_m.jpg http://i370.photobucket.com/albums/o...g?t=1325284354

Do not worry about your difficulties in Mathematics. I can assure you mine are still greater.
- Albert Einstein

take a walk down memory lane...

you might just be expecting too much from the connection?

The setup appears haphazard upon install...like: "thats it?" ...and the clip has a lot of slop after you put it on. - more like a prevention thing as opposed to a fastener

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Thanks, gents. I had a really hard time getting that hose out when I removed the head, too; the proximity of the oil filter housing is the problem. I can pop it in and out -- it's clearly "popping in" when it does go in -- but I don't see how the clip is preventing anything when installed. As noted, it's sloppy as heck. If the heater feed line wanted to pull out, it could, unless that clip could reach the groove in the heater line itself.

FSM said to lube with coolant, so that's what I did, and it will pop in and out w/o TOO much effort; I just can't get that hose in far enough. I was prying to the point that the whole engine would rock side to side. It's almost like the line or the fitting in the head are 1/8" off. Weird.

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1992 300D 2.5T
1980 Euro 300D (sadly, sold)
1998 Jetta TDI, 132K "Rudy"
1974 Triumph TR6
1999 Saab 9-5 wagon (wife's)

courtesy of GSXR.

Here are some pics for reference. If the head was rebuilt, perhaps they installed the wrong heater inlet on the head (wild guess)?

A picture of your issue would certainly resolve this. I couldn't find a close enough shot on Geoff's link or elsewhere.

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