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Old 11-30-2011, 01:39 PM
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Fuel line sizes for a 1976 240D (w115) along with some other ?s

I just acquired a 1976 240D, and I noticed diesel leaking from the return lines looping between the injectors. The car has sat for quite some time, so I know it will require some maintenance to get it going. I'd like to start by just replacing the fuel hoses all around. Anybody readily know the sizes I will need? I'd like to have it all on hand before I go ripping cutting and pulling. Also, is it common to have the oil cooler leak where the core attaches to the bottom tank of the oil cooler, or is there a more typical leak point that could be repaired without having to replace the whole cooler? Where is the secondary fuel filter? Thank you all in advance!

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Old 11-30-2011, 02:17 PM
toomany MBZ's Avatar
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3.2 mm for those "jumper" lines.
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Old 11-30-2011, 07:38 PM
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Regular rubber Vacuum Hose only will last several weeks.

Fuel Return Line/Hose size
Diesel Return Hose 3.2 X 1.9 mm For Diesel Injectors (Sold by the
Meter), 240D M616.912-, Brand: Cohline


Where to buy fuel return hose VW RAbbit
Diesel Injector return lines, where to buy? - PeachParts Mercedes ShopForum
The Thread with the part numbers
fuel return line replacement part - PeachParts Mercedes ShopForum

Injector return hose plastic tube
any lawnmower/chainsaw repair shop should have hose that will work too.
I bought a 50' box of 1/8" tygon clear fuel hose and the stuff holds up for about 3 years.
cost me like 15.00
The brand I used is Oregon, it is a Tygon fuel hose.
Tygothane (Saint Gobain is the Manufacturer)
U.S. Plastics is the retailer.

There is other threads.
DIY Repair Links
DIY Links by Parts Category - PeachParts Mercedes ShopForum

PeachPartsWiki: Do It Yourself Articles - Mercedes Vehicles
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Old 11-30-2011, 11:18 PM
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Thank you, I'll stop by Napa tomorrow to pickup some fuel-safe 3.2mm fuel hose. Now to figure out the Oil Cooler, vacuum pump and dash lights!

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