frustrating return line leak

[motomike33y]

at least one of the return lines is leaking on the injector on #2 cylinder on my 1.6 na.  I have replaced it, trimmed it, tried to zip-tie it...all to no avail.  I'm about ready to try to buy some viton lines, but wonder if there are other things I haven't yet tried.  suggestions?  thanks

[Quantum TD]

I've had a return nipple crack at it's base in the injector housing. No amount of fresh rubber will solve that. I had to swap the injector body.

[motomike33y]

anything cause cracking? or just age?  It was working well in my other engine until the rod went, so I put the injectors in the rabbit engine. Problem surfaced immediately.  I have other bodies if that is the problem

[maxfax]

Age probably doesn't play so much into it..  Just a good bump at the wrong time will usually do.. 

[rs899]

I have made the mistake of cutting the old return lines off in the past and making a nick in the nipple.  When that happens, it seems likely that any new line will leak.

[motomike33y]

I'll take it out this weekend and look, I think I have a glowplug bad also, so I'll kill a couple birds with one stone.

[motomike33y]

changed the top and fixed the leak.  now I've got a noisy injector tho and my pop-tester won't work.  sigh

[fatmobile]

How noisey.
 If it's banging, you don't need a pop tester to open it up and remove the piece of paint that is stuck in the nozzle,
 ha been there.

[motomike33y]

I'm going to take it out tonite and double check that I matched the right top, and the spring spacer.  It runs ratty when I start, but will smooth out when it gets warm and I'm driving 55.  It acts like its missing at idle or when first started.

[motomike33y]

had a 155 bar top, which looks the same as the 130, but the source of my problem was the spacer from the 155 rather than the 130 top.  different thickness and different hole.  switched and all is well.  now on to looking at the brake master cylinder-but that's another story.