What about the injector return lines? Is anyone using non-standard tubing there? The regular braided line only seems to last about a year on my cars with the new diesel formulation. I know someone has mentioned small engine fuel hose in the past as an option. What size? I ordered some injector return line from an online supplier (it's a house in Arizona) and I just got rubber vacuum line which is cross listed as injector return line.

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

Vinyl tubing(home depot) or Tygon tubing (order online) should work A-OK

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$60 OM617 Blank Exhaust Flanges
$110 OM606 Blank Exhaust Flanges
No merc at the moment

i used fluoroelastomer(sp?) on the return lines because its biodiesel rated... it works fine.

i also have some clear line running from the last return line to the filter housing. it's for lawnmowers/small engines. i found it at oreilly in a box on the shelf in that small engine area. its been on there for 6 months and it still looks fine. i believe its tygon.

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1981 NA 300D 310k miles

More Notes: from a parts place this info next to the Stock Fuel Return Line: Fuel Hose/Line; 3.2mm ID x 1.9mm;
According to this site: Convert inches to mm - Conversion of Measurement Units
1/8"= 0.125"=3.175mm
So 1/8" ID Hose is actually a little tighter than the 3.5mm stock Hose.

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84 300D, 82 Volvo 244Gl Diesel

Tygon, urathane and vitron are all diesel rated.

Vinyl is not rated for any fuel.

Is it worth a buck a foot to chance your vehicle becoming a rolling BBQ ?

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1985 300D 198K sold
1982 300D 202K
1989 300E 125K
1992 940T

"If you dont have time to do it safely, you dont have time to do it"

"The democracy will cease to exist when you take away from those who are willing to work and give to those who would not."

Picked some up today. Thanks.

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13