fuel injection line (cylinder 2) cracked in half!!

[ReubenG]

A) why would this happen? (the pump and lines are only a few years old)

B) I ordered a new line. Replacement seems fairly simple. Anything I should know?? (I have the Bentley)

[/URL][/img]

[ReubenG]

(1981 vw rabbit diesel 1.6 n/a)

[burn_your_money]

Prothe?

Is the 4th injection pump bolt right? The one at the rear of the pump?

[ReubenG]

yeah, i think it's the bottom rear on the pump. But when purchasing, it was obvious that I needed the #2 line I hope -- http://www.partsplaceinc.com/products/product-detail.aspx?keyword=VW+Diesel+Injection+Line+68-130-302&sku=13651

[ReubenG]

could this happen if I accelerate too quickly? Bentley says to accelerate from 35mpg to 55mpg in like 15 seconds... in 3rd or 4th gear...

[745 turbogreasel]

A) why would this happen? (the pump and lines are only a few years old)

B) I ordered a new line. Replacement seems fairly simple. Anything I should know?? (I have the Bentley)

Don't lose the little rubber holders, don't adjust timing without loosening the pipes first, keep the pump mounts tight.
Do not stand, sit, or pry on the pipes

[ReubenG]

I'm not planning on adjusting the timing... I can just plug in a new line... right?

[burn_your_money]

Yes, after verifying that all 4 pump mounting bolts are tight you can "just" plug the line in. Make sure that all the lines smoothly connect to the pump and injector without needing to be pried into position. If they are under stress, they will crack.

[ReubenG]

I see. Thank you. Also, it seems that it might be difficult to torque the injector line nuts down properly (with the line coming out of them and all...)  just snug them down fairly tight I guess?

[Dakotakid]

Yeah, just twist the wrench until you feel it give........

No, you simply gently tighten then down really only enough to not leak when running. If you just mindlessly tighten them down, you mushroom the sealing conical tip and then you shell out ANOTHER $23 (or whatever it was) for some more lines. Whatever happened to common sense?

[burn_your_money]

I think spec is 18ft-lbs. basically as loose as possible without leaks, which is surprisingly loose. 

[fatmobile]

Tighten them down a little looser than you think they need it.
 Then watch them when you start it up, swipe a finger to see if it gets wet.

[burn_your_money]

Because the fuel delivery is so low on these cars, you may need to take it for a spin around the block before you'll notice a leak.

[damac]

only been driving these 5 years and have a few being daily driven by family. all old originals and never had this happen.

clamps loose , start each one by hand, then tighten with wrench. finally tighten clamps

[ReubenG]

thanks to partsplaceinc.com for sending me the part I needed in less than 2 days.