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Fuel return line popping off

26K views 13 replies 4 participants last post by  Cosmin  
#1 ·
Fuel return line on the 1st injector keeps popping off and leaking diesel everywhere. The ‘o’ ring and R clip have been replaced but this is the 4th time coming out.
No mechanics can get to me.

Any suggestions?
 
#2 · (Edited)
#12 ·
Hi

Hi,
from reading your post, I think you mean the plastic insert that the little pipe goes on is popping out.
I've got the 1.6 tdci and the return pipes fit on the top, so slightly different to yours.
I did find though, that the plastic insert sometimes needed a slight tap to seat properly and sort of clip in snug, then the 'R' clip holds it in.
Check with a pin or a dart, something with a point, that there isn't a bit of the old insert still in there stopping it from seating properly. It would only take a tiny slither of debris to cause a problem.
Good luck
Bob.
 
#13 ·
If Bob is right about you meaning the plastic connector then it is very likely that a bit of debris is stopping it seating properly. It has just reminded me when I did mine the single leak off connector would not quite click in with the same snap the rest did and it did pop off after a few miles. Turned out to be a bit of the old connector had snapped inside the hole like a fine washer stopping the new one fully seating. A quick little turn with a small fine screw fished it and and been fine since.