Injector #2 pressure line cracked open 3 times same spot

[1984george]

I have replaced my #2 Injector line from the pump to the injector three different times. It keeps blowing and getting Diesel or WVO all over the engine. I fix it immediately after it happens.

-My pressure lines are hooked up correctly with the appropriate holding pieces to prevent vibration.

-The spot that keeps breaking is right where the line comes up to a sharp twist right before it hits the injector.

Any ideas what causes this or how to prevent it? It's a pain in the arse when you have to spent a half an hour on the side of the road fixing it every time, and that's only if you have back ups already in the car.

[82vdub]

Any ideas what causes this or how to prevent it?

Tighten all the injector pump bolts and make sure they are all there. 99.9999% sure you're either missing a bolt (at the high pressure end), or the bolts aren't tight. If the bolts are all there and tight, make sure your bracketry holding the IP is tight. The #2 line breaks because it has the most bends and is thus susceptable to cracking anytime stress is put on the line.

[1984george]

I will check all that. I'm almost positive I'm not missing a bolt on my IP. Thanks man.

[Fatmobile]

Seems like someone was on here with the same problem.
..and someone is making new injector lines with a slightly different bend on #2.
Price wasn't bad either.

[Op-Ivy]

Are the lines secured together with those clip thingies?

[1984george]

Seems like someone was on here with the same problem.
..and someone is making new injector lines with a slightly different bend on #2.
Price wasn't bad either.

That's something I'd look into, myself. I pretty much bought all of the used injector lines in the area.

However, recently deciding to replace all my injectors with newly rebuilt ones, I ran some "Seal All" along the twist of line #2. It hardened up nicely and I'm hoping that prevents a future crack. Sounds like a jerry rigged setup but we'll see what happens.

[1984george]

Are the lines secured together with those clip thingies?

Yeah they are supposed to prevent vibration. It's easier to just replace all 4 with new ones that are clamped together then frig around with the clamps. What's worse is that it's way too easy for the clamps to fall apart in your hand and drop down into where your timing belt is.

I think I'll invest in one of those long skinny magnet tools.

[rabbit_man]

Yeah they are supposed to prevent vibration. It's easier to just replace all 4 with new ones that are clamped together then frig around with the clamps. What's worse is that it's way too easy for the clamps to fall apart in your hand and drop down into where your timing belt is.

I think I'll invest in one of those long skinny magnet tools.

I've had those clamps off and never had the slightest problem putting 'em back on.......well everything's slow when you're working with big clumsy fingers

[vanbcguy]

That was me... I ended up buying some brand new Cohline-brand lines. They're a completely different shape where #2 meets the injector. I can't see them having the same problem again.

But yeah, you should have FOUR pump bolts...

[hagar]

1984george and ALL : Resonance and or Harmonics break a lot of lines..SO ? what did BOSCH do about it ?

They designed rubber dampeners installed at critical parts of the lines.. 3 Times ? you better start reading Forum it is all there and then some.

As a flyboy I have known about "Flutter" it will break the Wings off. . Remember galloping gertie the Bridge same thing . Some VW diesels have rubber danpeners on fron of Crank-shaft. , Tortional resonance will break the crank-shaft .I have two GM V8 cranks broken.

hagar.

[1984george]

That was me... I ended up buying some brand new Cohline-brand lines. They're a completely different shape where #2 meets the injector. I can't see them having the same problem again.

But yeah, you should have FOUR pump bolts...

Did you buy them online?

[vanbcguy]

Yeah, I don't recall which particular parts supplier I bought them from... I checked with Jack first but he didn't have any. I've found about 4 or 5 different parts suppliers that carried them.

The Cohline ones are the same for turbo and non-turbo applications. A lot of parts houses just list them as non-turbo, but the part number is the same for both.

[Quantum-man]

VW no.s for injector lines

068 130 301
068 130 301C [turbo]
068 130 302
168 130 302D [turbo]
068 130 303
068 130 304