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#1
09-26-2011, 09:39 PM
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Clear line to OM606 IP popping off
So here's a fun problem. The plastic fuel line fitting (603 owners, I envy your banjo bolts) on the clear line to my IP keeps popping off.
The first time I put it back on, I noticed that the elaborately designed clip, which works something like a V-clamp for intake/exhaust fittings, was bent from the fitting being pushed out of the corresponding socket in the IP. I bent the two arms that engage with the flange on the IP back into position, re-installed the fitting. No more than 200 miles later, it's already being pushed out and bending the clip again! What gives? My fuel economy is in the toilet right now and I am not a happy dieseler!
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RIP: 2011 E350 BlueTEC, Schwartz 81k (totaled by uninsured drunk driver) 1964 Unimog 404.1 (wrongfully towed by the city) 1994 E320, Brilliantsilber 208k (transmission shuffled off after sudden catastrophic fluid loss) 1982 300D, Silberblau under a blue repaint 256k (sold for parts) 1995 E320 Polarweiss, 131k (sold for parts) 1995 E300D Polarweiss, 287k (totaled by drunk driver) 
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#2
09-26-2011, 10:26 PM
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The replacement part for that line actually has a banjo fitting. If you (or your dealer) look it up in the EPC you'll see the bolt and washers which have to be ordered separately.
I'd be a bit suspicious of it popping off in the first place though. What are the chances your relief valve is stuck and it is building too much pressure in the system? The valve is a spring and ball in the banjo bolt for the return line on the other side of the pump. If you pull the crossover pipe and use a ratcheting box end wrench you can get to it but only one click at a time. I've never heard of one sticking closed and usually the problem is that the spring gets weak and the pressure it too low. Have you put a new o-ring on the fitting? If so, what are the chances it was a bit too thin and is not sealing well enough?
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'82 300D - Light Ivory, 2nd Owner (Back in the wind April 2013!) '95 E300D - White, grey interior. (Suffering from stuck/broken glow plugs) Deuteronomy 22:4- "Thou shalt not see thy brother's ass or his ox fall down by the way, and hide thyself from them: thou shalt surely help him to lift them up again."
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#3
09-26-2011, 10:35 PM
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This thread has the info on the updated line with the banjo fitting. After replacing all the o-rings on mine I'm leak free with the original fittings
 I found my fuel leak (OM606.190)
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'82 300D - Light Ivory, 2nd Owner (Back in the wind April 2013!) '95 E300D - White, grey interior. (Suffering from stuck/broken glow plugs) Deuteronomy 22:4- "Thou shalt not see thy brother's ass or his ox fall down by the way, and hide thyself from them: thou shalt surely help him to lift them up again."
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#4
09-26-2011, 10:54 PM
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I haven't done anything to the fuel system besides replace filters and injector return lines, so it shouldn't be a leaky O-ring. The fact that they updated this part with a banjo bolt and fitting makes me think that this was a known issue. I'll order the parts from the stealership tomorrow and see if installing the new line fixes the leak (and associated poor fuel economy).
__________________
RIP: 2011 E350 BlueTEC, Schwartz 81k (totaled by uninsured drunk driver) 1964 Unimog 404.1 (wrongfully towed by the city) 1994 E320, Brilliantsilber 208k (transmission shuffled off after sudden catastrophic fluid loss) 1982 300D, Silberblau under a blue repaint 256k (sold for parts) 1995 E320 Polarweiss, 131k (sold for parts) 1995 E300D Polarweiss, 287k (totaled by drunk driver)
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