Fuel Leak.

[8v-of-fury]

What would cause my return lines between injectors to leak. Or if it is leaking at the unions between hardline and injector... how do I fix that?

I cannot for the life of me get it to stop leaking, all four injectors and the head and block below each are soaked with diesel. I am using regular old #2 Diesel fuel, and it will leak immediately after starting the engine. I have blown through the return line and I can blow easily with lungs to the tank.

what else am I missing? gonna get some new return lines, maybe i need new hardlines? maybe i have a leak? 

Its rather annoying

[macka]

they are old and decrepit. Replace them. I bought my line off of ebay, it was cheaper after shipping then buying at the dealership.

[GEE-BEE]

EBAY ITEM ::   220338281895

You get a new fuel line from filter to pump, and new hardlines with gaskets

GB

If you need new 7mm return hose I have a reel of it....

[8v-of-fury]

Looks qaulity GB, as always .


I will look in to what I need to replace all the fuel lines. It seems a good thing to do. Question, with the metal hardlines that run under the car, what size are they? 3/8"? should be sufficient no?

[macka]

G,

  Why am I not surprised you have a reel of return line?

[GEE-BEE]

5/16 OR 1/4

Hey I found 50ft new for 35.00 buck's ( 7 mm )

GB

[8v-of-fury]

IT would appear that when taking the fuel return banjo bolt off the pump.. it takes a considerable amount of pressure from my lungs to blow air in to the tank.. do you figure there is a blockage? I mean how much force should be required to push fuel back through the return to the tank??

I figure I will put the other filter back on to eliminate the back in to the filter before going to the tank. 

[8v-of-fury]

I put the old style filter back in, with the feed only going through the filter.. and the return going directly back to the tank.

The return line through to the tank can be blown through with lung pressure.

With the passenger side return line disconnected and put in a bottle, (with the small return nipple on the pump blocked off) it only did a few dribbles in to the bottle.

I fear I may have a bit of a more serious problem.. While this seemed to help a bit, the leak didn't appear as quickly upon starting the vehicle.. If I take the end cap off the #4 injector and blow a low psi through the #1 injector return.. should it easily be able to blow out the #4 side?

[8v-of-fury]

I removed all the injector return lines and blew through each side of the injector with compressed air.

Diesel shot out of the opposite side on each injector.

I then put them all back on but the plug on the end and the other end going to the pump.. blew air in each end to see air and diesel come out each end again..

the leak seems to have possibly lessened however it still leaks and there is still fuel puddling on the tops of the injectors. got some oem cloth fuel line coming in sometime soon.. so hopefully it will completely solve the problem eh?

Dunno why it would be leaking anyway.. how much pressure is generated from fuel trying to make it back to the pump?

[theman53]

I never had a cloth line seal after I took it off. I hope that the new line fixes you up. If you take the return line off of the IP you can run it into a jar, it doesn't make much pressure.

[Rabbit on Roids]

all my diesels have toyota vacuum hose for all the small injector return lines. it fits alot better than the crap that is wrapped in fabric. and doesnt leak either. i fought with the VW cloth stuff forever, then found the perfect place for it, in the garbage. and also found a use for the miles and miles of vacuum lines ive pulled off carb'd toyotas

[8v-of-fury]

ok boys, diggin' this one up as she is still leaking..

Brett (Maxfax) sent me some purrdy new return lines (THANKS A TON BUDDY ) and they went on real nice. However I still have a leak.. and upon further speculation and investigation it appears it is leaking at the junction of injector and hard line. As the injector body is wet further up then the return lines are even at.. Also the block gets soaked after just a short drive. I had the return line off and in a bottle, and it barely had 4-5 drips after 15 minutes of running.. so there is no way the fuel is coming from them.. What do i do here guys??

I want to spend money on this engine, but I am also in the hunt for an AAZ. sooo i don't wanna go nuts.. I need advice!

WWJD?

[theman53]

http://www.autohausaz.com/search/product.aspx?sid=25510f55pemt1x45tvbkhy45&makeid=800026@VW&modelid=1282979@JETTA &year=1988&cid=22@Fuel %26 Air System&gid=11220@Fuel Injector Line

get a new line and see if it fixes it Junk yard is also an option.

[GEE-BEE]

Fix it with new lines from ebay seller moogie2498, and sell the motor and get a AAZ

Iam not sure what your time is worth , But I would be done with that and moving on to something else..

GB

Good luck...

[8v-of-fury]

So you'd be swapping in an AAZ a.s.a.p is what your saying GB? lol I need to find one still.