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DW8 fuel leak-off return lines R&R
#1
Hi all, first post after a year of lurking.  My 04 plate 1.9 has developed a strong diesel smell in the cabin with the fan on, and around the engine bay.  Not a big leak but I have narrowed it down to the leak-off return lines on injectors 1 and 2 (or is it 3 and 4? from left to right when looking at the engine from the front).  The braided hose between those injectors is sopping wet with diesel which then drips down to the base of those two injectors and onto the ground (I think).  The others are dry and fine, as is the rest of the line that I can see.  I've also got the classic only-starts-well-when-parked-downhill issue which points to air leaks there I guess?

Have had a look around the forum and elsewhere and it seems a common problem and also fairly easy to replace.  Don't have a Haynes manual but hoping to do this myself at home.  Any recommendations on which hose to buy and where from, also is there some kind of blanking plate that needs replacing?  Would love some step by step instructions if anyone could type them up for me.  I'm generally a decent bicycle mechanic but usually pay someone else to do car stuff -- however this fix does look fairly simple.  If I'm still having problems after the hoses are changed I will get an injector specialist to have a look.  Thanks.
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#2
Ebay has a meter of the braided hose for approx £4.00 . Just cut off the old stuff and push on the new bit.

https://www.ebay.co.uk/itm/250518492971?...xy-HtRYjod
2020 Rifter 1.5 allure
2010 B9 red XTR w a v. 
2001 1.9d DW8B white  Berlingo  
2005 2.l green Berlingo
2001 1.9d DW8B white  Berlingo 
berlingo 1.4 red multispace
1993 xud 1.9 red partner
[-] The following 1 user says Thank You to brodfather11 for this post:
  • mschole
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#3
Just following this up, I did manage to get a hold of some EOM return lines on ebay for a fiver, got the intake manifold off ok and installed them. Once the manifold was off I could see I needed both injector 1&2 and 2&3 done so it was fortunate the package came with 2 lines.

In the end it wasn't a hard job but a bit tricky pushing the lines onto the nipples without a lot of room to move around, lucky I have small hands.

Anyway it's running well now, no diesel smell or leak anymore, it starts better now too so that's nice.

Thanks!
[-] The following 1 user says Thank You to mschole for this post:
  • geoff
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