1984 300SD:
Ready to do regular scheduled service and notice fuel leaking around injector bypass hoses and want to replace them at this time. I've not done this before, (only had the car for 220000 miles).; can I expect any suprises with this replacement procedure or is it as straightforward as it seems?

Pretty straightforward, buy the correct hose from the dealer or order it here. Be careful not to lose the little plug on the last injector. Don't cut the old line off and nick up the connectors on the injectors.

It's pretty simple, just remove and replace - just DON'T damage the barbs on the injector bodies! If you replace the line at the end (the one that doesn't go anywhere), you'll need to put a plug in the line - an appropriately sized machine screw or bolt should work.

When I did mine, I used a pair of pliers to grab the old line firmly, but gently above the area where it is seated on the nipple. Then, I twisted back and forth while pulling upward. Some can be a bit stubborn.

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1982 240D, sold 9/17/2008
1987 300D TurboW124.133 - 603.960, 722.317 - Smoke Silver Metallic / Medium Red (702/177), acquired 8/15/2009
262,715 and counting

It's straight forward - make sure you don't cut the new hoses too short or produce any type of kink in those lines. The loops should have a very natural bend to them and not be 'stretched' to reach between the injectors.

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1987 Mercedes 300SDL; SOLD
1985 Mercedes 300D; SOLD
2006 Honda Pilot - wife's ride; 122K;
1995 Toyota Land Cruiser - 3X locked; 182K

Straight forward, the only surprise will come from buying it from the dealer. I paid $27 uncut.

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2002 Jetta TDI
1984 300SD (FOR SALE?)
2005 Acura TL
1970 442

Somwhere in the below threads is the VW part number for the same return hose and I have read that NAPA also carries it.
Where to buy fuel return hose
http://www.peachparts.com/shopforum/showthread.php?t=238219&highlight=Rabbit
The Thread with the part numbers
http://www.peachparts.com/shopforum/showthread.php?t=210922&highlight=return+line+part+number

Siknny 3/16 inch Vacuum hose will last about a week but it can get you buy until you get the real thing.
I used Silicone Hose ounce and after 1-1/2 years it never leaked but was rock hard when I removed it and could not be reused.

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84 300D, 82 Volvo 244Gl Diesel