I just reintalled my injectors after having them pop tested and cleaned. Now, the fuel return line on my 6th injector (last injector of the series: i.e. closest to the firewall) keeps splitting and popping off. This isn't the line with the end stub in it, it is the line that is connected to the 5th injector. Once it pops off, it sprays fuel everywhere and I get a crazy big mess. The return lines are brand new viton lines that I cut the exact length of the old lines.
Any ideas on why the line is popping off? What the heck is causing it?
Any ideas on how I can get all the fuel out of my injector cups aside from using a turkey baster and tons of paper towels?
Guidance appreciated. Thank you,

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Ed
-1984 Mercedes 190D 2.2 5-speed gray market(bought@30,000 miles) (Sold back to original owner@170,000 miles)
-1999 Mercedes E300DT (245,000 miles)
-1999 Mercedes S500 Grand Edition (80,000 miles)

many viton lines require clamps to hold them in place. not sure why, sometimes it is the diameter difference, sometimes it's the heat tolerance of them...

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 560SL convertible
1987 190D 2.5-5SPEED!!!

1987 300TD
2005 Dodge Sprinter 2500 158"WB
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

Thank you for the comment. I was thinking about putting a clamp down there as well, but I'm going to be pretty hard pressed to find something that is actually going to fit on that tiny fitting.

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Ed
-1984 Mercedes 190D 2.2 5-speed gray market(bought@30,000 miles) (Sold back to original owner@170,000 miles)
-1999 Mercedes E300DT (245,000 miles)
-1999 Mercedes S500 Grand Edition (80,000 miles)

motorcycle shops sell pretty small clamps. they'll have one that works.

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2009 E320 Bluetec 117,000
1995 E300D 306,000 Sold
1996 Ford Taurus LX 130,000 Sold
1985 300TD Still 225,000 Sold
2016 Ford Fusion 24,900

Good idea. There's a Harley Dealer down the street from me. Thanks,

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Ed
-1984 Mercedes 190D 2.2 5-speed gray market(bought@30,000 miles) (Sold back to original owner@170,000 miles)
-1999 Mercedes E300DT (245,000 miles)
-1999 Mercedes S500 Grand Edition (80,000 miles)

In the end, I used a wire tie from a bread bag to secure the return line to the injector. I tied the bread tie around the return line prior to securing it to the injector nipple. I then used needle nose pliers to gently work the line and wire tie over the nipple. Pain in the neck!

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Ed
-1984 Mercedes 190D 2.2 5-speed gray market(bought@30,000 miles) (Sold back to original owner@170,000 miles)
-1999 Mercedes E300DT (245,000 miles)
-1999 Mercedes S500 Grand Edition (80,000 miles)

Did the fuel spray come from the line that was separated from the injector or from the injector itself?

In my experience, there is little to no pressure in the return system.

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-Evan


Benz Fleet:
1968 UNIMOG 404.114
1998 E300
2008 E63


Non-Benz Fleet:
1992 Aerostar
1993 MR2
2000 F250

Why not try some non-viton Hose for trouble shooting.

One of the things that can cause too muc pressure inside of the Injector is if Combustion Gasses are getting into it.
Poor lapping of the Parts or the Injector halves not being torqued enough can cause that.
Heat Shield upside down?

You could try swapping the Position of the Injector and see if the problem follows the Injector.

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84 300D, 82 Volvo 244Gl Diesel

Why not use the proper hose? Viton is just a marketing gimmick.

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http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

Why so...

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#dieselFLEET
---------------
'97 E300
'99 E300

Because all fuel lines these days have similar or same qualities.

__________________
http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

O. I thought that the Viton stuff was what to get, guess it doesn't matter anymore? o-rings, lines, etc...

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#dieselFLEET
---------------
'97 E300
'99 E300

Bose, better sound through better marketing.

Sure viton is better than the 30 yr old rubber you are replacing. Other than its got the same qualities as the newer stuff. Plus, heat is going to kill any of it way before you will see a difference.

__________________
http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

The OEM fabric braided one time use hose gets very very tight on its own, in my VW days I had a freind who was constantly having the same issues, new original hose fixed that problem

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2012 BMW X5 (Beef + Granite suspension model)

1995 E300D - The original humming machine (consumed by Flood 2017)
2000 E320 - The evolution (consumed by flood 2017)

Where did you get the Viton hose? it should be 1/8" ID and 0.25" OD and I've used that (bought from McMaster-Carr) installed on at least 4 diesels and never had a blow off. Is the barb possibly damaged?
One forum member who was supplying Viton hose also used/recommended hose clamps but I left them off because they are a nuisance and also look goofy. I had no leaks on them either way.
(edit) Oh hey, if the end that comes off isn't cut away to expose new hose about a 1/4" back from the initial cut, its probably not going to fit tight.
DDH

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'95 E320 Wagon my favorite road car. '99 E300D wolf in sheeps body, '87 300D Sportline suspension, '79 300TD w/ 617.952 engine at 367,750 and counting!