My 1995 E300D is spraying diesel fuel from a crack in one of the fuel lines. The rubber line is connected to the top of the filter housing with a removable clamp. I'd like to buy a replacement line, but noticed that the other end of the line is connected near the left front fender with a metal crimp. There is also what appears to be a check valve in the line connected by the same type of crimps.

My question is, if I buy a replacement line from Mercedes, would I need a special tool for the crimped connectors, or could I use pliers or cutters to crimp? Is there an MB alternative to the crimped connectors? I'm too much of a purest for a non-MB part... I appreciate any help on this as I'll be in for a tow to a shop if I can't fix this myself (engine is soaked with fuel)...

Thanks!

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Chris

1995 - E300D - 115K
2002 - Lexus RX300
1999 - Nissan Frontier

Post a pic so I know what lines you speak of. There are several fuel lines on this engine.

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Benzmac:
Donnie Drummonds
ASE CERTIFIED MASTER AUTO TECHNICIAN
MERCEDES SPECIALIST 11 YRS

Benzmac,

This was taken standing at the left front headlight. The line comes directly off of the fuel filter housing, connected with the brass colored clamp (Phillips screw clamp). Fuel sprays from under the hose (only when running) right after the clamp but before the 90 degree bend. It sprays as if there's a split in the rubber after the clamp.

I'd like to be able to replace the 90 degree bend at the top, but the check valve you see in the line on the way down has the crimped clamps I mentioned. There's also another crimp further down near the left front fender.

Thanks for your help!

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Chris

1995 - E300D - 115K
2002 - Lexus RX300
1999 - Nissan Frontier

one time use only clamp and it is crimped on with a special tool.

It's function can be replaced by a regular hoseclamp without problems.

the reason they use it is that it is cheaper and faster to install in large quantites when at a factory assembly line for instance.

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/Per

MB E300TDT -98

I agree. I have taken many of these off and replaced them with 12 or 13mm clamps. It is marked on top of the clamp what size.

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Benzmac:
Donnie Drummonds
ASE CERTIFIED MASTER AUTO TECHNICIAN
MERCEDES SPECIALIST 11 YRS

Thanks for the responses - I fixed the spraying fuel line by cutting off the end of the rubber hose and re-clamping. There was a split at the end of the hose that was able to cut out. That took care of the most serious leak #1.

After fixing the major leak, I noticed another one - a consistent drip (about one drip per second while running) at a fitting on the side of the injection pump. This is a line that comes from the fuel filter down into the side of the injection pump. After checking my 124 Service Manual CD and talking to a local dealer to locate a replacement line, I found out that it had been modified to replace the original clip on fitting with a banjo bolt (bolt w/ a hole in it) fitting at the injection pump. No need to modify the injection pump, it's already threaded to accept the banjo bolt. I purchased the new fuel line, banjo bolt and washers. Fuel leak #2 fixed!

My question is on fuel leak #3. This picture of the fuel filter housing was taken standing at the right front of the car. There's a black braided line that comes from under the engine cover (starts at bottom left of picture) and connects to a fitting at the filter housing (I believe this is the return line). It leaks at its connection to the fitting. I tried cutting 1/4 inch off of the end of the line and reconnecting with no luck - the end of the hose was stretched and I thought sure this would work. It doesn't drip, but the outside of the line gets soaked w/ fuel when the car is run.

Can anyone recommend an approach for this leak? Do I need to replace the entire line, or is there some way I can fix it? There isn't a clamp on the line now but to my knowledge there never was. My only hesitation on replacing the whole line is that it seems like it would be just as likely to leak with a press-on connection. Am I missing a clamp?

Thanks for any help on this!

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Chris

1995 - E300D - 115K
2002 - Lexus RX300
1999 - Nissan Frontier

The braided line is available in bulk and cut to length. The # is 615 476 03 26. One unit is 1meter, the hose you need is 340mm and is the last of the series of return loops from each injector. The loops are 165mm (so says the parts book anyway). The stuff is cheap and doesn't remove well (it can't be removed and reattached). The rest of the lines will be tough to get to.

Work with great care around the hard plastic lines. We have found that once you start repairing the o-ring seals in one they all wind up leaking after being brushed against.

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Steve Brotherton
Continental Imports
Gainesville FL
Bosch Master, ASE Master, L1
33 years MB technician

Yep - I have the same problems with my 95 E300 Diesel.

I replaced both my fuel filters, solved the major leaks - but now I can see slow small drip like leaks.

Would anyone happen to know the part #'s that Chris / CSE300D used in fuel leak #2?
More specifically, I believe I am looking for:
Banjo Bolt
Fuel Pipe
Aluminum Seal

The CDROM lists the part numbers as:
Banjo Bolt 601 990 08 63
Fuel Pipe 601 070 53 32
Aluminum Seal N 007 603 012 113
but after searching Fastlane & Partsshop for the Banjo Bolt & the Fuel Pipe numbers - I could not find either one....???

Thanks for any help someone may provide.
Mark
95 E300 Diesel

Thanks to Phil at PartShop - there is a "Fuel Pipe Assembly" part no 601

It includes the fuel pipe, banjo bolt, & seal.

I'm having to look into a fuel leak this evening on my '95 E300D. Does the intake manifold have to come off to be able to get in there? (I'm thinking so!)

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Mark Herzig
1995 E300D 153K
1985 300D 142K (sold)
1979 450SL 122 miles (sold)
1992 500E 127K (sold)
1987 300SDL 132K (sold)
1986 300E 161K (sold)