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Old 11-15-2006, 04:48 PM
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Join Date: Jul 2006
Posts: 182
fuel lines

i am pondering fuel line replacement in a 1980 300d

can someone please tell me whats involved and how big a job this is??


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Old 11-15-2006, 04:53 PM
MattBelliveau's Avatar
Gotta another one...
Join Date: Jun 2005
Location: NE Ohio
Posts: 1,685
If you plan on replacing with rubber, not a big job at all. The hard metal ones may be a bit of a PITA.
1989 300E 144K
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Old 11-15-2006, 06:09 PM
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Join Date: Mar 2002
Location: northeastern PA
Posts: 437
I assume "line" means metal
Just did mine this summer. If you have a lift, not too bad. On ramps, still doable. Mine were totally rusted out just in front of the rear wheel.

I removed the old ones (try not to bend too much). Then take your new line (mine was 5/16 from Napa; 25' is sufficient) and bend it to match the old. tape them together.

I didnt feel like messing with it all as one piece, so i made each part in 2 pieces, again cut right in front of the rear wheel. A compression fitting worked fine, and you could probably even splice them together with just a piece of rubber hose. The hardest part is re-clamping them; if your bends aren't quite right, that can be a problem. On the PITA scale 1-10, I'd say 5.

Do the brakes while your down there, too. Flare fittings a must.
2004 E500 4matic; 72,000mi
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Old 11-15-2006, 06:12 PM
winmutt's Avatar
85 300D 4spd+tow+h4
Join Date: Apr 2006
Location: Atl Gawga
Posts: 9,332
Perhaps he meant return line? I just bought a meter of the return line from Phil here and patched the line that needed it. Some of the injectors further in the back around the linkage can be a real PITA.
1987 300D Sturmmachine
1991 300D Nearly Perfect
1994 E320 Cabriolet
1995 E320 Touring
2001 Eurovan FOR SALE
1985 300D car, sold and missed.
OBK #42
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Old 11-15-2006, 07:23 PM
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Join Date: Dec 2004
Location: Albany, OR
Posts: 4,845
I took it to mean the rubber lines. The rubber ones are easy. You can get a new set from **************.com for $50. It's pretty straight forward. In the engine bay you simple pull them all off and put the new ones on. If you are doing the rubber lines at the tank you need the tank to be as empty as humanly possible, or else you have to wait a long time for it to drain out. Then pull the old lines and put the new ones on.
Then pump the primer handle and crank her up.

'04 Jetta TDI Wagon
'82 300TD ~ Winnie ~ Sold
'77 300D ~ Sold
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