somewhat of a major problem - page 1 - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• somewhat of a major problem by jpedro on 15 Apr, 2010 23:45
• Well heres the story short..... I smelt diesel, got looking found the leak was fairly bad, was coming from under the hood. injector pump was soaked and everthing around, and while it was running there was a mist of diesel around it so i looked tightiend everything down and re checked, well to my suprise i noticed there was a crack on one of the steel lines for the second injector from the pass side, well theres the leak the line is craked, how can i fix this, im supposed to be heading out of town tomorrow afternoon and now my car decides it wants to wash itself in diesel. what is a quick easy fix to do this hard main injector line what you suggest.
• #1 by zagarus on 15 Apr, 2010 23:53
• i can only think of replacing the line, those have to hold a lot of pressure so I dont think you could easily patch it up without risk of it leaking again.   1.6TD?  I have spare lines i could mail you. Of course you wouldn't have them for awhile.
• #2 by 745 turbogreasel on 16 Apr, 2010 02:46
• Fill up real often
  
  Lines break from adjusting timing without loosening them, missing padded clamps, and getting sat on.
  I have heard of one person who made a successful weld repair, but I'd be hesitant.
  I know another guy who piped from the broken line back to the tank.
  I heard a rumor  truck shops  have emergency flexible line, but never seen it.
  While you are messing about there, remember that leak is at 1700PSI, and may case a significant injury if you try to block it with any part of your body.
• #3 by GEE-BEE on 16 Apr, 2010 06:40
• get a new set with new line clamp's
  
  Moogie298 ebay seller has them for 69.00 for a set
  
  You will need three clamp's, two doubles and a quad clamp.
  
  Remember I didnt tell you where to go , Just how to get there....
  
  Gee-Bee
• #4 by Smokey Eddy on 16 Apr, 2010 09:14
• If you're in a jam you could wrap duct tape around it to keep the mess down a bit? at least it wouldn't be spraying so hard... well it would be spraying just as hard it just would no longer be airborn
  unless of course the leak is significant enough that it just hydraulically cuts the tape... not to mention the tape would melt after a while...
  I'd go with paying Zagarus to ship them like ... over night delivery...
• #5 by truckinwagen on 16 Apr, 2010 09:21
• I had this happen to me a few years ago, nice plume of diesel every time the injector fired.
  
  had to keep driving it for a couple days, so I wrapped the line in tinfoil where the leak was to keep the diesel from getting atomized in an attempt to keep the car from catching fire.
  
  it worked too.
  
  but if you can afford to not drive the car until it is fixed, you should do that.
• #6 by jpedro on 17 Apr, 2010 11:16
• well i sucessfully welded the line back up and drilled the hole back threw and it works great, a big power imporvment starts easier now, i think it has been cracked for a long time and it just have out, and where it broke was right above the nut that goes on the injector on the second one in from the passenger side. id still like to get a new set but this will do for now i have a 120km each way comute to work so i needed it and my truck wasnt ready to insure yet, but thanks for the ideas.
• #7 by burn_your_money on 17 Apr, 2010 11:56
• Check all the pump mount mounting bolts to make sure they aren`t loose. #2 on the TD injectors always seems to fail first and if you don't correct the real problem you'll be back in that boat soon enough.
• #8 by 745 turbogreasel on 17 Apr, 2010 14:22
• Nice, what did you use to weld it?
• #9 by jpedro on 19 Apr, 2010 19:21
• i welded it with a stick welder, then i redid it cause it broke again and today it started to leak again so this time i brazed it and what mounts do i tighten or what is the usual problem of #2 cylinder.....
• #10 by jpedro on 19 Apr, 2010 23:32
• well now it broke yet again after i brazed it so now i have to track a injector line down which is going to be impossible where i live no one has any nor do the autowreckers. booo help please.
• #11 by Rabbit79 on 20 Apr, 2010 00:22
• I'm not 100% sure if this will work or not, but if you have a shop in town that makes hydraulic hoses for heavy equipment or farm equipment they may be able to rig something up for you. Most hydraulic systems start out at 3000 psi (the excavator I run at work runs at 4900!), so hydraulic hose should be able to handle the pressure, and hydraulic oil is petroleum based so I wouldn't think the diesel would cause any trouble. The problem you'll probably run into is finding the correct ends for the hose. If you take your line in they may be able to use the nuts off of it if they have to. Another possible quick fix would be to cut out the bad part of the line and slide some hydraulic hose over the two good ends and then tighten the crap out of the clamps. I'd be a little leery about doing that though because once you cut the line you're completely screwed if it doesn't work. In my experience with high pressure hydraulic lines once they get a crack they're done. All the welding and brazing in the world doesn't last, they might hold for a little while but not for long.
  Parts Place out of Michigan ( www.partsplaceinc.com ) sells an emergency injector line that is made from flexible steel mesh, so it will work on all of the injectors. I have one but have never had to use it so I can't report on how well it works, but you may want to think about getting one in case you ever have this problem again.
• #12 by GEE-BEE on 20 Apr, 2010 07:08
• Dont forget the Vibration clamps ( 3 ) two 2 piece and 1 that holds all four lines...
  
  GB
• #13 by BigDiesel359 on 20 Apr, 2010 07:33
• Are the VW lines like some others where they have a coating or lining in them. If so, wouldn't trying to repair it, especially trying to cobble it together with a stick rod, ruin this lining? I know on my old 6.5L Chevy turbo diesel it was advised to make sure to not bend the lines or this coating may flake off. I believe it is the same on my 5.9 Cummins as well. Either way, I would not waste my time on something like this, replace it and forget it.
• #14 by jpedro on 23 Apr, 2010 17:11
• So some bad new! i checked everything over and everything is tight.  and the way it should be. the other lines are fine and not broken or anything. but i got a new line for it and guess what it lasted about a whole day. and it snapped in the same spot as before. so now im goin to burn this POS cause i cannt think of what else is wrong with it. zagarus do you have the #2 injector line and the clips that hold all the lines, if so what would you want for them please let me know you can email me at [email protected] please and thank you.