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Old 07-01-2007, 09:39 PM
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Viton non-braided fuel return line

I purchased Viton hose to use for the fuel return lines. It's not braided. Has anyone used non-braided hose for their return lines? Can it cause any problems?

The hose came with copper clamps but my engine (606 962)does not have any clamps on the return line. If I do use the Viton, do I need these clamps?


1998 E300TD
W210 025
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Old 07-01-2007, 09:44 PM
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I assume that you tried a search, but perhaps you need to try to refine it. I've not done this, but I have read a number of posts where people did. Not on a 210, but the hose is the same on the older cars.

One of these posts mentioned using a piece of fine wire around the tube, wrapped several times and secured like a bread tie. I'm sure that you don't need much tension, but you might need some since the fabric braid will supply tension to the original hose.
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Old 07-01-2007, 09:48 PM
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I replaced those return lines about two weeks ago myself. I found (locally) some viton hose with a cloth braid over it. I don't think it would matter if you were missing the cloth braid -- not like it really insulates much or anything. The fuel will be hot, but is not under much pressure in the return lines.

The fittings to the injectors are just a press-fit -- no clamps or other retainer necessary if you have the right diameter hosing.

Good luck -- it was my first time replacing these lines on my own, and the whole job took about half an hour, including pulling out the rotted old lines and cutting the new lines to fit.

Cheers, John

EDIT: Matt L beat me to the post, and his argument for why the braid is useful makes a certain amount of sense -- first time anyone ever gave me a good reason for it being there, when none of the other tubing in the area has it.
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Old 07-01-2007, 09:49 PM
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Sounds like you may have gotten a "kit" from JADAVIS?

I've read he includes hose clamps "in the event" they are needed.

If they go on tight I would leave the plastic cover off and drive it a couple days and observe if it leaks. If not, button it up.
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Old 07-01-2007, 10:38 PM
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IMHO the fabric cover could only protect against radiant heat. Not a huge concern on that side of the engine, but very useful near exhaust pipes.
'83 300D Turrrbo 295K miles
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Old 07-02-2007, 01:27 AM
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I include the clamps because that is what I used on my 603 engine. I had the intake manifold off to do the glow plugs and did the hose while I was there. I didn't want to take the manifold off for something silly like a return line leak so I used the clamps. I have to agree with just about everyone who has posted that you don't really need them. I'm just an overly cautious kind of guy.

Since I can't seem to find my bag of clamps and everyone seems to agree that we don't need them I think I am going to drop them from my site. The clamps that is.

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Old 07-02-2007, 10:59 AM
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As long as the hose goes on good and tight you don't need clamps, and don't worry about the non-braided thing. I have had my non-braided viton injector return lines on for over a year and they still look great, no leaks, and no problems.
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Old 07-02-2007, 11:50 AM
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I did try a search and found some good info but I was unable to find any discussion on the exact purpose for the braiding. My thinking was that the braiding is there was to provide "compression" around the fittings so the tube would be snug and to keep the tubing from stretching under pressure.

Yesterday I installed the Viton tubing without the clamps and everything looks fine. The clamps are in the trunk with some tools to install them.. just in case.

This forum had been a great source of info and has saved me hundreds of dollars so far.

Thanks guys


1998 E300TD
W210 025
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Old 07-02-2007, 02:09 PM
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I have been using 1/4" o.d. non-braided polyurathane hose for return lines for years with no problems.
Ron Schroeder
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'83 300 Turbo Diesel 2 tank WVO
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Old 07-02-2007, 02:42 PM
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Originally Posted by WD8CDH View Post
I have been using 1/4" o.d. non-braided polyurathane hose for return lines for years with no problems.
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Old 07-02-2007, 03:58 PM
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I used Jadavis's kit on my 603. I did not use the clamps as they didn't really fit around the line that tight. Mine have been on for 6 weeks and haven't come off yet. I think they will be fine.

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Old 07-09-2007, 10:22 PM
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I'll be buying some polyurethane tubing to replace the old braided material.
I just got the machine and started running biodiesel. Now I gotta play catchup to replace all the old rubber that's rotting out. I'll let ya'll know how it works.
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Old 07-10-2007, 07:51 PM
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viton is high temp material, no need for braiding. only about 8 psi in return lines, no clamps needed with correct size hose
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Old 06-25-2008, 05:57 PM
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Location: Aurora IL
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material of return lines ?

What about the1/4" and 1/8" clear tubing sold at Advance Auto Parts.
It's fuel line for small engines, and i hear it's PTE, or PTFE ? Is that polyurethane, or as good as ?
I tried replacing one of the old ( quite hardened ) clear lines ( 6mm ? ) with this 1/4" stuff.
It seems a bit loose, so I used little clamps, but- will the material hold up ?
I am running B99, now.
Haven't found a supplier for proper tubing, yet. Guessing that my 617.152 engine uses 6mm in fuel system, and also 3 or 4mm I.D. clear line, to banjo fitting.
Is that right ?
And, is Viton of the correct size available somewhere, at a reasonable price ?
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Old 06-25-2008, 09:51 PM
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where to get viton...

go to . they have all types of hoses and seals.
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