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Old 08-10-2006, 11:28 AM
Registered User
Join Date: Aug 2006
Posts: 19
injector return lines


I just purchased an '83 300 D Turbo. I'm really impressed with the car and how well it rides and feels especially considering how old it is.

This is my first MB and my first diesel, so it's really a learning experience.

I've noticed a strong fuel smell and I've noticed that one of the injector return lines is moist, and the associated injector is wet with a little fuel running down the engine block from that area. It's not a lot, but everythign is a bit moist. From what I've read, I need to change the injector return lines, which looks like an easy-enough job.

QUESTIONS: Do I have to get the original MB part? Does my local AutoZone have something I can use? What's the ID of the tube? etc.?

I'm happy to use the right part, but I want to to it today, as it stinks and is giving me a headache and sore throat (it rained this morning so the sunroof was closed and the windows mostly up!).

Thanks for any info!

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Old 08-10-2006, 11:37 AM
Join Date: May 2002
Location: Blue Point, NY
Posts: 25,396
The correct part is available from suppliers other than the dealer. Whether AutoZone will have it is another story altogether.

A "generic" replacement hose may, or may not seal properly around the nipples.

Also, be very careful in removing the old lines. If you cut them off the nipples, be sure that you do not nick the nipple in any way.......or you'll have a permanent leak.

Installation requires some patience to get the line all the way down on the nipple. Leave the hose in the sun to warm it up for this endeavor.
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Old 09-22-2006, 06:20 PM
Registered User
Join Date: Sep 2006
Location: NorCal
Posts: 54
Is cutting the old lines the best way to remove them? I have tried pulling them, but no luck. Do you just cut through the braid a bit to loosen them??
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Old 09-22-2006, 06:23 PM
Registered User
Join Date: May 2006
Location: Fayetteville , NC
Posts: 89
I purchased the return hose from the dealer, 15.00. Tried a few auto parts stores, the all the auto parts hose too wide to get a good seal on the injectors.

bob 1981 240d
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Old 09-22-2006, 06:31 PM
MattBelliveau's Avatar
Gotta another one...
Join Date: Jun 2005
Location: NE Ohio
Posts: 1,685
Check .
1989 300E 144K
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Old 09-22-2006, 09:28 PM
Larry Delor's Avatar
What, Me Worry?
Join Date: Jun 1999
Location: Sarasota, Fl.
Posts: 3,114
I used a single edged razon blade to cut mine loose.
Went to a foreign repair shop, and asked them for some hose since the rubber stuff from a mcparts store leaked.
It is a truism that almost any sect, cult, or religion will legislate its creed into law if it acquires the political power to do so. Robert A. Heinlein

09 Jetta TDI
1985 300D
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Old 09-23-2006, 01:41 AM
Diesel newbie ;-)
Join Date: Aug 2006
Posts: 412
Phil carries them here. I know you want to do it now, but I bought my set from him and it was like $8.00 with a couple spares.
Get a good grip on the hose and pull, it will come off.


PS, welcome to the group. I got an 83 DT for my first diesel too and had the exact same first question
Dearship wanted $80 to change those lines out
'83 300D Turbo
Current: ???K mi - 19.2mpg -> 17.4mpg -> 22.9mpg ---> ODO Died
bought at: 233.8K mi - 10MPG For $1.00
3.5 cylinders work: 320 320 100 340 280
Got insurance? FarmersReallySucks.Com
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Old 09-23-2006, 01:53 AM
JWJ JWJ is offline
Mechanically challenged
Join Date: Sep 2005
Location: Raleigh, North Carolina
Posts: 395
The first time I changed these I pulled on the lines and they broke leaving some tubing around the nozzle. They were hard as a rock. It took me an additional hour and an exacto knife to remove the remaining tubing. It must have been years since they were changed.

I now use Viton lines because of B100 and haven't had the same issue in over 2 years.
1983 MB 300D - > 430,000 miles - Deep Blue - Bilstein Comforts - 0-60 in 24 seconds - 27MPG
1985 MB 300TD (wagon) - > 275,000 miles - Manila Beige - Thule rack - 0-60 in 18 seconds - 22 - 25MPG
Biodiesel, Mobil Delvac 1, and Viton fuel lines!
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Old 09-23-2006, 08:27 AM
Registered Shadetree
Join Date: Aug 2006
Location: Wilmington, NC
Posts: 676
Changed mine out the other day. I was on a return trip from Atlanta to Wilmington and the fumes were killing me. Stopped at stealership in Columbia, SC. $26 for two meters of hose . Will be ordering Viton from McMaster-Carr asap as I'll be running my new 300sd on b100.

Anyway -- my old hoses came off with a slight tug, They were fuel-soaked to the point of being be mushy!

1998 E300 +310,000K
1996 E300 +460,000K

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