But I could use some advice on how best to fix it.

On this diagram, it's at the bottom of 107 where it connects to the pump. But here it shows a banjo bolt, I don't think mine has that. It has a clip like the one at the top left corner near the number 41, but it's kind of hard for me to get a good look at it.

With engine idling it's actually wiggling around and in and out, and the clip feels loose. (yes, I am losing a lot of fuel!)

So my questions: How exactly is this connected? Does it have the clip and banjo bolt? Could the banjo bolt just need be to be tightened? (There is a lot of vibration there!) Do you think this can be done without taking the intake off?

I have a package of viton o-rings from Fryerpower, and I ordered all the plastic fuel lines from Fastlane yesterday. Will these be necessary to fix this?

Thanks for all your help!

Todd

__________________

All I can tell you right now is that on the black fittings with O-rings and white clips, the clips should be loose and rattly when the connector has been properly secured. These clips are for releasing the two "paws" that snap onto the rim of the female part of the connection.

When reconnecting the lines, make sure the clip is loose, coat the O-rings with a little Diesel fuel then gently twist and press them into place until you hear a little "snap".

__________________
-Evan


Benz Fleet:
1968 UNIMOG 404.114
1998 E300
2008 E63


Non-Benz Fleet:
1992 Aerostar
1993 MR2
2000 F250

Thanks KarTek.

I did some more searching and discovered that I have the old style metal clips, and that the new ones are plastic. Also the updated style for that particular connection is upgraded to a banjo bolt from a clip. (If I am not mistaken.) Hence my confusion about the diagram. I wonder, does this bolt come with the new fuel lines I just ordered?

__________________

If you ordered using your VIN you should get the correct part.

If you've got a banjo bolt it probably just needs to be snugged up; if its a clip on fuel line it could be the oring or the clip itself that is preventing the seal.

Use a flashlight and a mirror to get a good look at it.

__________________
Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)

The banjo bolt is an update. I had the same issue. Original fuel line had no banjo. Ordered full set of lines from Phil, got the one new line with banjo, said WTF? (and to answer your question, the new line did not come with banjo bolt or washers, BTW, they have to be ordered separately) Researched it and found that the banjo is the updated version, and it will in fact work even if you originally had no banjo - the hole in the IP is threaded internally.

But now here's a question for the pundits. I just installed my new banjo line. But the dealer sent me 2 washers, presumably one for under the head of the banjo bolt, and one to go on the IP. That's how I installed it, and so far, so good, no problems.

But that diagram you linked seems to show only one washer for under the head of the bolt.

I dunno, but my way seems to be working fine. Is there a standard "Banjo bolt protocol" which says always have a washer under the head of the bolt AND the object to which you are bolting?

Rgds,
Chris W.
'95 E300D

Thanks Terry,

I didn't use my vin when ordering. Oh well, will have to wait and see what I get.

It's definitely a metal clip, and the whole fitting visibly moves in and out when idling! I know that ain't right.

The question now is: Can I replace the o-ring without taking the intake off? It's tight in there, but I am on the fence about it. The main fuel lines to and from the tank are difficult to move out of the way. I don't have a garage, so that is why I am hesitant to do that much work in this winter climate.

Will have to wait till tomorrow, busy with work now.

Thanks all,
Todd

Chris, just saw your post. I'll call Fastlane and order the bolt and washers. Thanks!

__________________

My turbo has one banjo fitting on the cly head side of the IP. It is installed with stacked washers.

__________________
Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)

I changed the o-ring. No more leaks, whew!

Discovered that I had much more room to work by taking the fuel filter off. I also changed out the other rings that I could easily reach. The hardest thing was figuring out how the darn clip worked in that cramped space.

Hopefully this will get me through the winter at which point I'll get the intake off and replace all the plastic lines.

Thanks all!

Todd

__________________