Leaking Injector at rubber "Plug" what to do?

[Doakster]

Had my injectors rebuilt recently and what ever barb I put the rubber "plug" on it will leak. I've even tried to reuse my old plug and the new plug.

Wondering if anyone has had this happen. My next step would be to put just a little bit of RTV on the barb exterior of the barb and see if that stops the leak.

[Doakster]

Blew threw from the return line on the pump through all the injectors and out where the plug was installed, basically blew the whole return circuit out.

Barely any resistance at all, just a little but nothing that I wouldn't have expected when blowing the lines and injectors out all in one.

[92EcoDiesel Jetta]

Did you by any chance use a knife to cut the old plug off and scored the return nipple in the process? Try to run you fingers over the nipple and feel for scoring. Look at it with a magnifier and clean it up with 600 grit wet dry paper.

[Rabbit on Roids]

x 2 on the stick. use some normal rubber vacuum line too. the fabric sheathed line VW uses is garbage. all my lines are toyota vacuum lines. i believe i have the head of a 16penny nail in the end for a plug now. but with the toyota vac lines, they fit better on the injectors too, so i get no leaks from my return lines.

[92EcoDiesel Jetta]

x 2 on the stick. use some normal rubber vacuum line too. the fabric sheathed line VW uses is garbage. all my lines are toyota vacuum lines. i believe i have the head of a 16penny nail in the end for a plug now. but with the toyota vac lines, they fit better on the injectors too, so i get no leaks from my return lines.

Vacuum lines generally are not rated to handle fuel. You may want to check the Toyota vac line rating and make sure it meets SAE 30R7. A stick may work as a plug for a while but as the hose ages, the stick may pop out and you will dump a lot of fuel before you find out it's leaking! Buy the correct plug! It's only $1!

[Rabbit on Roids]

check what likes for what rating?
-throws all the technical stuff out the window-

SCREW IT! if it works, then it works. i dont care if its rated to be a diesel fuel return line.

every time i buy a cap, it ends up leaking. so i made my own.

[Doakster]

Did you by any chance use a knife to cut the old plug off and scored the return nipple in the process? Try to run you fingers over the nipple and feel for scoring. Look at it with a magnifier and clean it up with 600 grit wet dry paper.

I've tired my old plug and my new plug both on the number 1 and 4 injectors, both leak.

I'm going to inspect the barbs a little more and maybe to one more blow down test. Honestly is was really easy to blow out the entire return circuit, plus all of my return lines are brand new.

The return line I got seals each barb really nice and tight, no issues with those leaking just the little plug. If all else doesn't work I may end up making my own plug with some extra return line that I have.

[Doakster]

Checked things over again.

- Blew through each injector independantly, each injector is equally as easy as the next, no restriction in the fuel line itself.

-Checked all the barbs for burs, no burs found.

The plug still leaks....looks like it might get the RTV treatment

[92EcoDiesel Jetta]

did you pull the plug to inspect? Maybe it's split? I'd try a new plug or a section of return line with a plug (a machine screw that goes in tight) and skip the RTV.

[Doakster]

did you pull the plug to inspect? Maybe it's split? I'd try a new plug or a section of return line with a plug (a machine screw that goes in tight) and skip the RTV.

The plug is good, no cuts. This is for my brand new plug and my old plug. They both leak just at the base of the plug, so fuel is going past the barb and out the bottom of the plug

I might try a section of return line

[maxfax]

SCREW IT! if it works, then it works. i dont care if its rated to be a diesel fuel return line.

Just keep a close eye on it..   Some regular vac line will turn to goo after being exposed to anything petrolium oriented (like diesel) long enough. Toyota may use a higher grade of vac line that will be okay..   The typical parts counter vac line ain;t worth crap....

[Doakster]

You blew through the return line back to the tank and only that line (not hooked up to the pump)?

Nope I blew through the return line that is off the out bolt feed from the injectors, the plug that was leaking was removed...so effectively I blew out the entire circuit from the out bolt through all the injectors and out the barb where the plug was leaking.

Then I blew out each injector independently. Either way I did it, there was no restriction, real easy to blow out through the lines.

The only thing that changed was that my injectors were rebuilt and i installed new return line between each injector and the return line to the out bolt.

[Doakster]

Did some more trouble shooting....and I have good news and bad.

I checked the return line going from the fuel filter to the tank, turns out it did have a clog in it. I could not blow back to the tank. I removed the return line at the tank and completely blew out the line with compressed air. So that completes the entire return system, there is now no restrictions and I can blow threw the entire circuit easily just with my mouth.

I put the plug back on thinking I was good, and low and behold, it still leaks. I had enough of it and made my own plug out of return line and a rubber plug, now it doesn't leak.

But that's just the start of my problem. On top of this my freshly rebuilt injectors have been leaking all along from the body to the boss, so they are going back to the rebuilder to get relapped.

And in my two hour drive when the plug was leaking, I believe enough diesel leaked in between the engine and trans and got on the clutch, because now my clutch is slipping.

It's ridiculous how much trouble a little fuel leak can cause.

[maxfax]

It's ridiculous how much trouble a little fuel leak can cause.

At least it didn;t catch on fire too.... 

[Doakster]

It's ridiculous how much trouble a little fuel leak can cause.

At least it didn;t catch on fire too.... 

Something even more scary....I has a fuel line fitting burst on my Powerstroke awhile a good. They just happen to put the fitting right next to the exhaust manifold. I was driving around like that for about 2 mile before I noticed the smell of diesel and my fuel gauge dropping very fast

When I stopped I found diesel spraying like a fire hose on the manifold. I couldn't believe it didn't light up, that was a scary one.