Club 80-90 Forums

3rd time now. always number 2 why?
its a 1y engine from a 97 golf, all stock setup etc, number 2 injector pipe has broken off just where just where it goes into the injector(twice) and this time it has split along the bend where it goes in, i would like to blame vibration but there are cable ties every 10mm, aswell as the usual anti vibe stuff as standard.....anyone got any ideas? this is happening far to often

it cant be much more than vibration.i recon.have you used brand a new pipe each time.or second hand...

When you fitted it last, did the two ends line up perfectly before you tightened the nuts, or did you have to push/pull it into place a little before tightening?

It is possible to induce some stress in the fuel line at this point due to this or as you nip the nuts at the back up. Don't feel you have to massively tighten them up, the torques are relatively low, despite the pressures. This combined with general vibration may have been enough.

Is the rear lower bolt holding the pump to the bracket/block tight?

Do you have the pipe clamps in place & are they in the correct place (check a Haynes manual or look for clean sections on old pipes. Diesels are shocking for vibration, so if the pipe goes into resonance at a common rpm, it'll shake itself like a guitar string until it snaps off (Land Rover had problems with Freelanders doing this with the gearbox & IRD & it would snap gearbox cases at specific rpm over quite short periods!!)

Are the pipes able to hit something like the engine lid? Don't know how much clearance there is in a 2wd but maybe the pipes are slightly taller than JX ones or the engine lid is cracked so can't take weight?

I'd only surport the pipes in the orginal way as that should be enough and overconstraining them might cause problems.

Is the pipe the correct length? If its not the same length as the others it will knock itself apart through vibration. Funny things diesels!

the pipes length doesnt matter, the maritime folks use longer lengths anyway to avoid vibration problems (1).
(2) the lid has padding and is not marked so it aint rubbing etc.
I went to RN Diesel and they made another pipe up (£10) i have checked the pump is secure(it is), i have fitted the new pipe with vibration spacer thingy and about 30 million cable ties.. if it brakes this time i am going to consult NASA

They may use longer pipes but I can assure you they all have to be exactly the same length. If one is extended, they all have to be extended.
A lot of diesel engines have a coil or two in the pipe to take up the extra length.
If you have had one made up which isn't the same length as the others then that is where the problem lies.

yes the pipe is the same pattern as the original.

yes the pipe is the same pattern as the original. i was going to ask him (if it fails again) to extend all of them, diferrent run etc