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Yikes! Apart from learning the hard way how to work with banjo fittings, there's one thing missing from your setup. Nobody ever mentions this, and I think it's extremely important.

ALWAYS have a GOOD fire extinguisher within arms reach when working on fuel systems!!

Especially when it gets cold and the air dry, a fire that burns you badly, destroys your car and burns down your garage and house is only one itty-bitty spark away.


Now, having said all that, one thing that can make those washers leak is if the banjo pipe got torqued or dinged during the work. If the loop of the banjo isn't perfectly flush and level with the pump, the surfaces won't seal up correctly. Also, if you nicked or got plier marks on that surface, same deal. If it's just twisted a bit, you can use pliers (with leather to prevent marring) to get it straight again. If you've scarred the sealing surface, you may have to replace that part.

Here are some pictures. If you look closely you can see some form of drip mark on the banjo fittings. It doesn't look like a lot but when the car is running it drips out a lot of gas! :(

Are you sure you installed a washer on both sides of that banjo fitting?

I did EXCEPT for the top one actually, I didn't put it in on one side but did on both sides on the bottom one. Then It still leaked so I knew it had to be because it was missing that one washer. So I took it apart again and placed the washer there but it still leaked.

Could it possibly be when I took the bolt off to put the washer that I needed in there, that the other washer went bad? I heard they were a one time use washer.. ughhh dang it.. lol I didn't think that could be the problem because it was a brand new washer that was on there for like 20 minutes... Could it be it?

Sure that they are tight, remeber to hold the pump with a wrench and then tighten the banjo bolt.

I'll recheck and make sure they are tight tomorrow as it's dark out now. I was able to move the car and put it in the RV parking on the side of the house. Starts up and runs great, just need this stupid leak to go away!!! :mad: I'll take better picture tomorrow for you too. Those ones kind of sucked...

If its tight and the washers are in place it should not leak. Don't give up it just a leak.

I REALLY do not like the gap I see between your fuel filter and bracket, Having that filter hang by the pipes is going to cause a stress fracture on those pipes, you think you have a leak now? wait untill one of those pipes break under pressure. You really need to think this thing through, you may want to take the car to a real M/B technician and have him fix your F/P issues before you really do have something bad happen.

I thought it was tight but i'll double check, you never know. The washers are in place but i'll tighten it tomorrow.

I'll take some better pictures and let you know what's going on. Hopefully I can fix it. Thanks again for the help!

Yeah what is going on with that bracket. It seems that the filter and the top pump are not exactly in line, that would cause that line to leak.

I'll redo that tomorrow. I need to tighten the bracket anyway. It looks mickey mouse lol

There actually was a fire extinguiser there it just wasn't in the picture. I stole it out of the 220D. I was very careful made sure nothing electrical was around and the battery was disconnected.

The washers were in bad shape and I tired reusing them which was a bad idea lol but I got OEM ones from MB and it's still leaking like I hadn't changed them. I'll check the surfaces for scarring tomorrow as I'm doing this all over again for the third time to make sure everything is in place.. Hopefully there aren't any nicks or dings in the sealing surface.

IT IS DONE!!!!
 

Finally after two days of trying to get these stupid pumps in and working 100% they are in, working 100%, and leak free. THANK GOODNESS! :eek:

Turns out it was leaking from where the main fuel bolt (don't know its name) screws into the actual pump. I had everything pretty tight but I didn't notice I had to tighten it there. It wasn't until my dad took the old pumps to the mechanic to see if he could give us clues and sure enough, he said that was the last step I'd missed. So I took it all apart again today, went and got more new OEM copper washers from MB to make sure there would be no leaks, rewired and put back together... I was pretty nervous about the first start but we cranked her up and no leaks. It was so amazing lol

I drove to the gas station to put more chevron in and all seems well so far. She hasn't stalled out yet but we'll see. I'm hoping the pumps were the main cause of this. Thank you all of you who helped out with this!!!!!!!!! Here is a picture of me pointing to where it needed to be tightened.

**Also, if I never had to smell or deal with gasoline again, it'll be too soon.. Gasoline is the most evil substance lol

Good job. Hopefully it will not stall out anymore.