The weather was finally decent enough last weekend for me to do some long-planned work on my 240D. After replacing some fuel lines and filters, I moved on to the tank strainer and accompanying line. I bought a 5-gallon fuel can that I can get under the car and my plan was to remove the flexible line from the tank at the non-strainer end and feed it into the can to drain the tank. Well, I couldn't get the line off because the hose clamp screw is rusted in place. I tried lots of PB Buster with no success. It's going to have to be cut/broken off somehow. So does anyone have a good idea for how to do this? It's a tight area to work in, so that limits the possibilities. Also, I want to minimize the amount of spilled diesel, so ideally, I would cut the clamp off without disrupting the fuel line and then could just pull the line off quickly and into my can. The only thought I had was using a Dremel tool to cut the screw or clamp. Even though I am aware that diesel is not all that flammable, I'm rather hesitant to throw sparks around that area. Any thoughts?

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1980 240D 4-spd 185K (The Tooter)

You can try "nibblers" to cut the metal band.

Before Dremels hit the scene I used files, nibblers and large wire cutters. The place to cut the band is where it bends to accomodate the screw for clamping.

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RRGrassi


70's Southern Pacific #5608 Fairmont A-4 MOW car

13 VW JSW 2.0 TDI 193K, Tuned with DPF and EGR Delete.

91 W124 300D Turbo replaced, Pressure W/G actuator installed. 210K

90 Dodge D250 5.9 Cummins/5 speed. 400K

I'd dry up the diesel as best as possibe, and whip out the million RPM air powered cut off wheel. Just tap the clamp on the band and it will cut right through, just don't cut the hose much and it won't leak.

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1999 SL500
1969 280SE
2023 Ram 1500
2007 Tiara 3200

The supply line coming out of the tank, if its the original one, has a "factory, non adjustable" clamp. If you cut it you will find a barbed fitting which a new hose and adjustable clamp can be fitted to. I would syphon all the fuel out you can then jack up the passenger side of the car so you wont get a diesel bath. I would also change the 2 lines on the driver side of the tank as a leak there can drip on your CV boots.

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"