I've read many posts in the archives with no clear consensus on the best line material for replacing them.

To those of you who have changed them -what type of replacement line did you use? What was the inner and outer diameter of said line?

I am aware that these lines can be purchased as complete parts, but would much rather re-hose myself if possible.

__________________
1981 240D 4sp manual. Ivory White.

They are quite inexpensive pre-made. You will not save very much doing it yourself and You may find it difficult to make a leak-free connection using home equipment.

It’s about $50 all up -which is fine- but I’d also read OEM quickly turns opaque.

__________________
1981 240D 4sp manual. Ivory White.

I replaced mine with rubber fuel hose and clamps. I just tried to see if I could read the size on the hose but I could not. Looks like I used 1/4" ID Hose.

I heated the plastic just enough that I could pull it off cleanly. You need to tape the jaws of a channel locks or the pliers you use to hold onto the banjo/nipple end as it gets too hot to hold on to and you don't want to scratch them.

I used a propane torch to apply the heat. Just back and forth waved the flame by it.

You will need new crush washers if the originals are aluminum. If they are copper you can use the propane torch and heat the copper crush washers cherry red and let them cool or plunge them in cold water. Either one softens the copper crush washers and you stand a chance of being able to re-use them.

As was previously stated the plastic lines start of rather clear but discolor with age. Making it difficult to see if you had air bubbles from an air leak.

I changed to the rubber hoses back in 2008 because I did a filter mod to the Spin-on Filter. I have had zero issues with the rubber hoses. Which is no surprise.

__________________
84 300D, 82 Volvo 244Gl Diesel

I can't remember if the originals were aluminum or copper -but does it matter?
I changed them a couple of years ago to copper from a crush washer kit.

__________________
1981 240D 4sp manual. Ivory White.

When you are using new ones it does not matter. If for some reason you have to remove something on the road that has an aluminum crush washer and have to re-use it there is a higher chance that the aluminum one may leak. Unless they were over tightened and deformed Copper Crush Washers can be reused several times. And if they leak they can be heated as I said which softens them and you stand a good chance of getting even another use out of it.

__________________
84 300D, 82 Volvo 244Gl Diesel

I get that. I was wondering if there was some quality intrinsic to aluminum...
Noticed pelican sells aluminum crush washers specific to this application.

__________________
1981 240D 4sp manual. Ivory White.

The intrinsic quality of aluminum seems to be that it costs less then Copper and works at least once.

And, if you took your Mercedes back to the Dealer to be worked on like they want us to do the Dealer has new aluminum crush washers for the job.

I also suppose there is a minor issue of shipping parts all over the world and a big box of aluminum crush washers is cheaper to ship and less likely to be stolen to be sold as scrap.

The idea for annealing/softening the Copper Crush Washers so they can be re-used comes from my former Boss's Navy Machinist Mate Manual. Official government approved method.

I have used the method quite a few times and it works as long as the crush washer is not badly deformed.

The only place I see that Mercedes did not use the aluminum crush washers is in the delivery valve area of the Fuel Injection Pump.

__________________
84 300D, 82 Volvo 244Gl Diesel

I bought new ones for my '82 240D and they're opaque when new and have not changed color one bit .

*Much* easier to see air bubbles in the new pipes .

I never see bubbles unless I run the fuel completely out .

__________________
-Nate
1982 240D 408,XXX miles
Ignorance is the mother of suspicion and fear is the father

I did then what I knew how to do ~ now that I know better I do better

I appreciate the explanation, been wondering about this for a while.

Nate -good news. That was the intention behind replacing these lines.

__________________
1981 240D 4sp manual. Ivory White.

If you want see through fuel lines you should have them.

__________________
84 300D, 82 Volvo 244Gl Diesel

Shern ;

I've had this 1982 240D for close to twenty years and the more I drive it the more I like it over my coupe or 7 passenger wagon .

As soon as S.W.M.B.O. stops driving it, I'll dump my beautiful gray market wagon .

The coupe I'll prolly let go too when I no longer want to support / maintain two old Mercedes .

The 240's are slow but if you're not in any hurry they're fabulous cars ~ roomy, comfy, ride nice while handling better than many 'sports cars' , safe an
d so on....

I guess I just like econoboxes .

I think my 1959 VW DeLuxe Beetle is viable daily transportation too, go figure .

__________________
-Nate
1982 240D 408,XXX miles
Ignorance is the mother of suspicion and fear is the father

I did then what I knew how to do ~ now that I know better I do better

Are you kidding me? I love this thing.
Yes, they may be the slowest cars on the road but the handling is surprisingly good... compared to 617 w123s, weight distribution perhaps?

I semi-dream of getting a 5sp and dropping a turbo in. Whether this will ever be a practical reality is the question.
Financially, it's certainly a foolish move. By the metric of sheer enjoyment however... I've made worse decisions.

__________________
1981 240D 4sp manual. Ivory White.

I’ve heard that the 240s don’t deal well with a turbo. Hard to replicate factory engineering.

5 speed sounds like fun. And work. If I had Jay Leno money, I’d put an M52 into my E30 325i with 450k. Having a hard time letting go of that car. But I like my SDL pretty well also.

__________________
1986 300SDL, 362K
1984 300D, 138K

Well ;

Adding a turbo is fun right until the engine blows in a few weeks / month .

A 5 speed manual is a very good thing too but they're mostly all gone now .

Once you learn to keep the tires at their optimum inflation and how to drive it spiritedly so the engine remains in it's sweet pot RPM/power wise, the slow acceleration won't bother you as much .

As I've said many times : if I had to choose one, I'm pretty sure I'd keep my 240D plodder sedan .

Try chalking the tires then driving it spiritedly ~ my '82 with only me in it, needs just about 40 P.S.I. cold to have the best traction and rolling resistance .

Of course, different tires (I run Michelin Defenders) will require more or less pressure .

I went with the original 175/R14 tires like M-B specified and the better handling and lighter feel is amazing .

__________________
-Nate
1982 240D 408,XXX miles
Ignorance is the mother of suspicion and fear is the father

I did then what I knew how to do ~ now that I know better I do better