So I was replacing the tierods on the '95 tonight and I noticed the was a little fuel leaking down from somewhere above. After finishing the tierods I went above for a look. It looked like the the leak might be coming from the fuel line that runs from the prefilter to the lift pump - at the lift pump end. I figure the o-ring had had it, so I decided that I would try to take care of it. I manged to get it disconnected at both ends, pulled out the line, replaced the o-rings with new Viton rings and then proceeded to try and get the line back in. Well, it was obviously more dificult going back in because of the nice new o-rings. Because I had left everything in place (didn't pull the maifold - although I just had it off the other day to replace all the glowplugs) I was trying to use a small pry bar to reach down in there and get a little leverage to pres on the back of the plastic connector and pop the end of the connector back where it belongs. All of the sudden - snap - the freakin plastic connector breaks right at the thin spot where the o-ring fits on. Now I am out my car for at least tomorrow - good grief!

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'95 E300D ("Tank") - 231,000 miles
'79 240D ("Biscuit") - 197,250 miles (Sold)
'83 240D ("Ding-Ding") - 217,000 miles (Death by deer)
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"Back off, man. I’m a scientist” ~ Peter Venkman

I know exactly how you feel...

When I went in to fix the wires on my alternator the oil cooler line ended up breaking and the alternator bracket bushings completely disintegrated from all the moving around when I took the alternator out, then on top of that when I tried taking the bracket off to replace the bushings the second bolt holding the bracket will not come off.

It was a nightmare and I was on a time crunch to get it ready for the so cal gtg. Thankfully it's over for now but I still need to replace the bushings for the bracket.

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2007 BMW 328XI

I did this same thing to a friend's '96 the other day. Only we didn't know it till he found a large puddle in his garage the next day. We must have busted it trying to get it back on with those tight new o-rings. Luckily I had some new lines for my '95 that I hadn't put on yet.

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JB Weld or JB Quick is all I have to say.

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1993 W124 300D 2.5L Turbo, OM602.962
2000 Chevrolet Cavalier, 2.4L DOHC
2002 Ford Explorer, 4.0L SOHC
2005 Toyota Prius, 1.5L

http://www.fuelly.com/sig-us/40601.png

"Next time" use a little grease on the "O" rings. . .

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82 240D Manual 277K and still rolling!
02 Volvo S60 AWD For Sale

That is what I was thinking this morning - if I can find the peice that broke off, I may go for the temp fix. I have a new line coming into the dealer tomorrow, but this comes at a very bad time so anything would help right now.

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'95 E300D ("Tank") - 231,000 miles
'79 240D ("Biscuit") - 197,250 miles (Sold)
'83 240D ("Ding-Ding") - 217,000 miles (Death by deer)
______________________________________

"Back off, man. I’m a scientist” ~ Peter Venkman

Excellent thought - thanks.

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'95 E300D ("Tank") - 231,000 miles
'79 240D ("Biscuit") - 197,250 miles (Sold)
'83 240D ("Ding-Ding") - 217,000 miles (Death by deer)
______________________________________

"Back off, man. I’m a scientist” ~ Peter Venkman

Well, I managed to find the broken off end of the fuel line connector. I was stuck in the female end (within the filter/prefilter housing). Of course, I had to remove the intake manifold to be able to even see if it was in there. What a bugger to get out. I had to tear at the new oring with a dental pick and then fashion a little hook tool out of wire hanger to get behind it and pull it out - not easy though.

I put the JB Weld to work and it is currently drying. I placed the old flattened o-ring back on before I stuck the pieces together - I want as little resistance as possible when I try to piece it back together. I figure I'll give it four or five hours to cure and then give it a shot.

Although the new line is coming in tomorrow, I really need my car for the morning - and to go get the new line . We'll see how it goes. I guess since I have everything torn apart I will go kill some time replacing other o-rings. Of course, I'll probably end up breaking something else.

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'95 E300D ("Tank") - 231,000 miles
'79 240D ("Biscuit") - 197,250 miles (Sold)
'83 240D ("Ding-Ding") - 217,000 miles (Death by deer)
______________________________________

"Back off, man. I’m a scientist” ~ Peter Venkman

Nice Neanderthal skull you got there. Is that 'The Old Man of La Chappelle'?

Methinks I need an avatar.

Codifex
1981 240D ChinaBlue (found an engine - hope it's good)
1983 300DTurbo w/sunroof

No, but that is a good guess from a small avatar. It is actually "Atapuerca 5" from the Sima de los Huesos ("Pit of the Bones") Cave located at Sierra de Atapuerca, Spain. Amazing site with an incredible amount of hominid remains. Atapuerca 5 dates to approximately 300,000 years ago.

I would suggest picking your favorite hominind fossil skull as an avatar, but then again, I do enjoy looking at all the things people come up with here - if it were all hominid skulls it would be pretty boring.

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'95 E300D ("Tank") - 231,000 miles
'79 240D ("Biscuit") - 197,250 miles (Sold)
'83 240D ("Ding-Ding") - 217,000 miles (Death by deer)
______________________________________

"Back off, man. I’m a scientist” ~ Peter Venkman