Now the 240D is drooling fuel ... - PeachParts Mercedes-Benz Forum

BodhiBenz1987 · #1 03-10-2009, 07:21 PM

... out of the banjo fitting on the side of the IP. Leaking bigtime, just started today. I had a hard time doing a search because I'm not sure exactly what this would be referred to as ... it's the big bolt that connects the hose from the top of the fuel filter to the IP. I'm guessing it's seals around the banjo fitting ... would this be the appropriate seal? Hollow bolt seal

Diesel911 · #2 03-10-2009, 09:23 PM

Any Copper washer that is close to the size you need will do.
Out Here were I am Ace Hardware and NAPA sell copper washers and I have an assortment of them I bought from Harbor Freight.
The Aluminum ones cannot be reused as often as the Copper ones (heating the copper ones Red Hot softens them again).
I would make sure that it is not the Plastic tubing that has cracked. If so what is left of the plastic tubing can be heated with a butane lighter and pried off. 1/4 inch Goodyear SAE30R7 fuel line sold at many auto part stores + hose clamps can replace it.

If you have any extra Oil filters the Copper washer that comes in the kit may fit.
I measured the Banjo Bolt on my extra IP and it is .470 = 11.94mm meaning the washer ID is most likely 12mm; the closest American size is 1/2 inch; and it looks like that will work.

#3 03-10-2009, 11:38 PM

I got tired of looking for copper washers, so being that I work at a machine shop, I took some aluminum bar stock, chucked it up in a manual lathe and made my own alum. washers. If you have any problems finding new ones, I can make some for you to the dimensions you want, and ship them to you. All I ask is re-imbursment for shipping. No charge for the washer.

Diesel911 · #4 03-11-2009, 12:56 AM

Quote:

Originally Posted by 83240D

I got tired of looking for copper washers, so being that I work at a machine shop, I took some aluminum bar stock, chucked it up in a manual lathe and made my own alum. washers. If you have any problems finding new ones, I can make some for you to the dimensions you want, and ship them to you. All I ask is re-imbursment for shipping. No charge for the washer.

What ID did you drill them to?

I am finding it hard to believe that the origional washers suddenly failed.

The only time I have seen them leak is after the Banjo Bolts have been removed and they have been reused or there was some previous damage like over tightening of the Banjo Bolt.

I have seen only a few Banjo Bolts loosen due excessive to vibration.

BodhiBenz1987 · #5 03-11-2009, 01:00 AM

Quote:

Originally Posted by Diesel911

What ID did you drill them to?

I am finding it hard to believe that the origional washers suddenly failed.

The only time I have seen them leak is after the Banjo Bolts have been removed and they have been reused or there was some previous damage like over tightening of the Banjo Bolt.

I have seen only a few Banjo Bolts loosen due excessive to vibration.

The bolt itself does not seem at all loose. Maybe it's not leaking from where I think it's leaking from. But it's definitely dripping from that fitting ... I suppose it could be a crack in the base of the plastic hose that I can't see. It did strike me as odd that the leak came on suddenly ... I saw no signs of it earlier, while I was changing the return lines.

Diesel911 · #6 03-11-2009, 01:31 AM

Quote:

Originally Posted by BodhiBenz1987

The bolt itself does not seem at all loose. Maybe it's not leaking from where I think it's leaking from. But it's definitely dripping from that fitting ... I suppose it could be a crack in the base of the plastic hose that I can't see. It did strike me as odd that the leak came on suddenly ... I saw no signs of it earlier, while I was changing the return lines.

After breaking 1 of the plastic tubings going to my IP I decided to raplace all 3 with the 1/4 inch rubber hose as stated in my past post. So it is not a big deal if the plastic is leaking.

#7 03-11-2009, 02:44 AM

I made one for my fuel filter bolt. After changing the fuel filter, my copper washer would never reseal. I made an aluminum one, with what I remember to be a .715 i.d., and a 1.00 o.d, and a thickness of about .100, I made one that was thick, and it hasnt leaked yet.

JimmyL · #8 03-11-2009, 10:27 AM

I purchased mine at the dealer for a buck or so apiece. No need to machine one really.....

BodhiBenz1987 · #9 03-11-2009, 04:52 PM

Quote:

Originally Posted by Diesel911

If you have any extra Oil filters the Copper washer that comes in the kit may fit.

Good call! The 603 filters come with two washers, the smaller of which I usually end up pitching. Well, that smaller washer is a perfect fit. Fortunately I had 10 oil filter kits in my 300D's trunk, so I grabbed a couple washers from there and popped them on. No more leak. I did make a huge mess, though, and had a bear of a time bleeding the system. Fuel spills out from the hand pump quite profusely when pumping it, so maybe there's something wrong with that pump? I did get it all bled eventually and running fine, though. Hopefully the fuel will now stay where it belongs. Thanks for the tips.

#10 03-11-2009, 06:05 PM

Well jimmy, I work 3rd shift, so i am alseep when the dealer is open. It took me total of 10 minutes to make it, so it came out faster... and cheaper "free" to make one myself. It is also 4 times thicker than any you can buy. So it wont curl, or warp when you tighten it down. Maybe its just my mistake, but I got sick of the weeping fuel filter bolt, after making one, no more leaks. But if a person can make it to the dealer to buy one, I say gor for it. My luck, theyd have to order one, so I would miss out on sleep, twice, for a $1 washer....lol

JimmyL · #11 03-11-2009, 07:14 PM

Quote:

Originally Posted by 83240D

Well jimmy, I work 3rd shift, so i am alseep when the dealer is open. It took me total of 10 minutes to make it, so it came out faster... and cheaper "free" to make one myself. It is also 4 times thicker than any you can buy. So it wont curl, or warp when you tighten it down. Maybe its just my mistake, but I got sick of the weeping fuel filter bolt, after making one, no more leaks. But if a person can make it to the dealer to buy one, I say gor for it. My luck, theyd have to order one, so I would miss out on sleep, twice, for a $1 washer....lol

I was just talking about me! Wasn't meaning to disparage your approach at all. Just there aren't many of us with machining skills so we have to go in other directions.......

#12 03-11-2009, 08:10 PM

cool, it was just a solution that worked for me.

I am anticipating getting my injectors back from BgKast. He got them in today. After seeing the "diesel smell" thread, and this "drooling 240D" thread makes me miss driving Myrtle. But in time, Myrtle will have new Monark nozzles, and no more injector nailing. YAY!!!!

charmalu · #13 03-12-2009, 12:47 AM

Quote:

Originally Posted by JimmyL

I was just talking about me! Wasn't meaning to disparage your approach at all. Just there aren't many of us with machining skills so we have to go in other directions.......

Jimmy, all you need is a $20,000 machine to make a 10¢ washer, you ain`t cheap now are you? I hear about you rich cattle and oil men

.

those three plastic fuel lines get stiff and brittle with age, and will crack easy after 20 plus yrs. I broke one when I was replacing my engine, snapped like a potato chip.
If those things are brown and not clear, they are old, bought one from the dealer and was amazed at how soft and bendable they are, and the price.

But since I always keep my car concourse ready

, can`t be too careful. have to keep up my image you know.

Charlie

JimmyL · #14 03-12-2009, 01:12 AM

Quote:

Originally Posted by charmalu

Jimmy, all you need is a $20,000 machine to make a 10¢ washer, you ain`t cheap now are you? I hear about you rich cattle and oil men

.

Charlie

Cattle? I have 3 chickens: a rooster and 2 very nervous hens!!

No cattle at this time, but the youngest daughter and the spousal apparatus would like a couple of donkeys. [insert jack-ass joke here, especially you Cap'n]
Cecily, we have bled all over your thread. Sorry.....
Good to know you got the leak stopped. Since it just 'all of a sudden' started leaking I just new it was a cracked line. Weird that the washers gave out, but I guess not that surprising. It took me 2 washers to get the one sealed on top of a spin on filter.

charmalu · #15 03-12-2009, 01:50 AM

Jimmy, just wait untill your daughters drag home some of those two legged Donkeys

that will make your nervous.

Change your spin on filter bracket with one of the later ones with the two rubber O rings on the large bolt. Don`t know what yr they went to them, my 85 has it. seem to be less trouble, think I changed the O rings once in 10 yrs.

Charlie