PeachParts Mercedes-Benz Forum - 2006 E320 CDI weeping/leaking fuel line(s) R&R?

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- - 2006 E320 CDI weeping/leaking fuel line(s) R&R? (http://www.peachparts.com/shopforum/diesel-discussion/382402-2006-e320-cdi-weeping-leaking-fuel-line-s-r-r.html)

I like the factory clamps. On my first fuel filter change I was ready to replace them with the worm-gear clamps because I assumed I would break the factory clamp.

If you carefully wiggle the screwdriver in the right spot under the top "plate" it pops right open. Try not to twist the clamp out of shape.

I've now reused the clamps on the lines at the fuel filter at least 20 times.

This is the proper tool for these clamps...sets and removes them without damage.

https://www.amazon.com/dp/B00Z3PQHWM

I've been trying unsuccessfully to upload a photo of the black fuel line, showing the pinpoint location of the hairline oozing of the fuel leak.

It's back of the clamp about two inches.
There's enough slack in the fuel line to cut it, and re-clamp. I'm going to do that for now. -If it works, that is.

Comments and questions;

1) My CDI only has 69K miles on it, so I'm certain the black hose fuel lines are original. I don't see 8' of fuel line, as one of you guys stated. Are there several feet out of view? Is fuel line a lot cheaper online than at the MB dealer?

2) how the heck would I get access to removing that front plate beyond the serpentine belt and radiator? Talk about a tight area!

SkidRow I would love to see the pictures. As you may have figured I am not much of mechanic but gain lots of knowledge from folks like you on the forum.

OK.....I did the slice and re-clamping at the fuel filter on the obvious leaking black fuel line hose.

Wiped the whole thing down drying off the diesel leakage. Started it up, and there's weeping from the other black fuel line hose at the fuel filter.

So, I've got to make a black fuel hose run to an auto parts store called Import Auto Parts about 6 miles from me.
My nearest MB Dealer is 18 miles away.

About the plate at the front of the engine that protects the fuel lines from the serpentine belt - held on by 3 screws, that the two fuel lines go to the front of the engine block from the fuel filter? I can get that if doing a double fuel line replacement. I studied it some, and I could do it.

Don't know why pics are failing the upload to the forum. Just tried again just now. Oh well.

No injector fuel leakage whatsoever on this 2006 I6 CDI.
Other than dusty, it's clean as a whistle.

Quote:

Originally Posted by Skid Row Joe (Post 3660767)

You have 4 fuel hoses on top of the motor. I ballparked that they are each shorter than 2', so 8' of hose will easily cover everything. 1 hose from hard pipe to outer fuel filter fitting...65psi. 1 hose from inner fuel filter to inlet on HP pump...65psi. 1 hose as return line from HP pump to "T" at center of manifold...7psi, and 1 hose as return line from rear of engine (collecting return from rear of fuel rail and all the injectors) that goes to other side of "T" at center of manifold...7psi.

That front plate is a little tricky. 3/8" ratchet, 1" extension, torx socket. That puts the ratchet handle between belt and fan shroud, giving "fingertip" access to ratchet handle.

Common issue cropping up on W211 E320 CDIs?

One of the fuel lines coming off the filter was the one that split on me while I was in a remote area in CO in 2015. Sounds like having some extra hose and/or razor blade may be a good thing to carry in the trunk for W211 e320 CDI owners.

Quote:

Originally Posted by chronometers (Post 3661357)

Yes. The razor blade or pocket knife is key to make necessary cuts.

That was the one I saw with a hairline crack weeping fuel. It makes a turn where mine was oozing 2" back of the clamp.
The other hose is oozing @ the clamp. I'll report after replacing that 12" line of black hose.

Thanks for all yall ongoing support and help!

Is the 5/16" black hose fuel line @ O'Reilly, AutoZone, Pep Boys suitable/rugged enough for the CDI diesel fuel? I just didn't get to the import auto supply independent before they closed for the weekend.

Part numbers for the four rubber fuel hoses.

648-070-10-81 Distribution to pump
648-070-12-81 Filter to pump
648-078-07-81 Filter to fuel tank
648-070-11-81 Supply line to Y distribution

I don't have measurements, but I know the lines to/from the fuel filter are different sizes.
It only takes 2 days on average for online M-B dealer part vendors to get special order parts in (if not in stock).

Quote:

Originally Posted by Skid Row Joe (Post 3661423)

Quote:

Originally Posted by MB_FanAddict (Post 3661494)

Quote:

Originally Posted by jay_bob (Post 3659668)

The only caution I can throw out (and this is probably true for any CAD-modeled engine)...

The LP fuel hoses on my OM606 and OM642 are specifically molded to fit around obstructions in the engine bay. Regular fuel hose will not be so molded and may be difficult to fit into place without kinking. On the 603 the hose runs are just gentle sweeps between components so everything works with just regular hose cut to length.

May have to pull the old hose and use it as a template. Form the new hose with a heat gun and a pan of ice water to heat, bend, and set it in place. If you don't have a heat gun but have a gas stove top, that would probably work too.

I know on the 642 they went to a fancy assembly of push on connectors at each injector for the return lines, not sure if that was used on the 648.

Quote:

Originally Posted by jay_bob (Post 3660099)

For the e-torx socket get this set
https://www.amazon.com/gp/product/B0002NYBVO
Not the one from Hazard Frought. The HF set does not fit the splines correctly since it is a Chinese copy and can strip out the bolt. The Lisle set is US made and they paid the $$ to license the Torx design properly.

The Lisle sockets fit very snugly on the bolt. In fact you have to be careful because an E12 socket will "almost" sit down on an E10 bolt and if you are not careful that will strip it out. Found that out the hard way on my OM642 oil cooler job. Luckily it did not destroy the bolt and it was a one use only bolt that was getting replaced anyway.

Quote:

Originally Posted by spark3542 (Post 3660041)

...and if you do find bad injector return lines, replace them with this:

E320 CDI return fuel line replacement with Teflon Tubing - Mercedes-Benz Forum

I bought everything exactly as described and it worked like a charm.

Jay Bob - I'm extremely thankful for your information. I read it and will compare Torx fitting brands. Nice to learn of the 642 differences.

MB_FANADDICT - very helpful! Getting the actual MB part numbers.

Spark - thank you for above Teflon return lines info!

Quote:

Originally Posted by MB_FanAddict (Post 3661494)

Thanks for posting those 4 hose numbers!

The All Imports Auto Parts had them on back order. I'm making a run to the MB dealer for the part.

The diesel fuel is flowing/fizzing out of the top of the assembly that is on top of the fuel filter. Right under the torx screws. The torx screws won't tighten - they won't tighten, but the screws aren't stripped. How is this assembly taken apart? I can't figure it out. The center screw in by fingertips black plastic screw has an o-ring at it's base that's intact. When I turned the ignition to the second turn, to refill with diesel fuel after replacing the short black hose - now it's apparent where the fuel's leaking from like crazy. Any help taking assembly off to inspect and maybe replace appreciated! No photos - can't get them to upload - sorry!

Are you referring to the water sensor on the fuel filter? If so it sounds like one (or more) of the rubber o-rings on the stem no longer seals. How long (many miles) ago did you replace the fuel filter?