Coming home on Thursday I could feel the tell-tale loss of power that signals a plugged spin-on fuel filter. I've known since I got the 240D in May that I was going to need to clean the fuel tank; the previous owner had neglected the car for several years, and I was sure that there was going to be gunk in it. As a matter of fact, I was running down the fuel level as low as possible to minimize the amount of dirty fuel I was going to have to pump out - however, that apparently had the effect of concentrating the very, very dirty fuel!

So, anyway, last night I started the process of removing the tank and got stuck on the very first step: the fuel sender is tight on there like a son of a gun. I can't budge it with the limited leverage of a pair of channel-locks. Is there anyone in Portland, Oregon who has a 46mm socket that I could borrow for a day? Or a suggestion on where to find a cheap one? Worst case it looks like I can order a $10 off-brand through Sears.

Thanks,

Kurt

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- '79 240D - engine swap complete! Engine broken in! 28-31 mpg! Lovin' the ride!
- '86 190D (W201-126) - 2.5 NA engine, 5 speed, cloth interior, manual climate controls, 33-34 mpg (sold to forum member).

I agree that the right tool is best. And I have NO CLUE, since I am a newb to these cars, if you have a back hat shelf with a first aid kit. But on my 560 I read to unscrew the plastic panel tab, lift up the shelf from the front ends a bit and slide the kit out. From there you can reach in and under with a channel locks. Worked great for me.

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1991 560 SEL / 185k miles
1992 750il / 17k miles - project car

Did you try getting to it through the trunk?

Now that you mention it, I need to remove that vertical trim panel in the trunk anyway... maybe then I can contort myself in a way that gives more leverage (imagines rowing position with feet braced on inside of fender).

Although, I'm a big fan of the solution that involves the 46mm socket, a 3/4" drive breaker bar, and a FOUR FOOT cheater pipe! A guy can dream, can't he?

Kurt

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- '79 240D - engine swap complete! Engine broken in! 28-31 mpg! Lovin' the ride!
- '86 190D (W201-126) - 2.5 NA engine, 5 speed, cloth interior, manual climate controls, 33-34 mpg (sold to forum member).

Try Harbor freight, they are the king of cheap chinese tools.

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I'll arrive in Portland Friday night the 10th and could bring my 1-13/16" socket with me if you haven't come up with a solution by then.

Jeremy

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"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

If for some reason you are able to do as you plan; You could add some Startron Biocide that has an enzyme that kills and breakes of the dead bodies of what is growing in the Fuel Tank so that they do not plug up so many Filters.
Next if you are willing to keep your Fuel Tank 1/2 Full you could swap positions of the Fuel Inlet Hose and The Fuel Outlet Hose (Cigar Hose).
Doing this would have the Fuel returning to the Fuel Tank back flushing your Fuel Tank screen while at the same time the the Fuel being sucked into the Fuel Supply/Lift Pump would now be drawn from a positon above the bottom of the Fuel Tank (why you need to keep the Fuel Tanl 1/2 full all the time).

If you did the above with the Startron and the Hose Swap and drove for a while like that you might end up with a clean Tank and Fuel Tank screen.

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84 300D, 82 Volvo 244Gl Diesel

I have always removed it with channel locks, as you tried.

but the used tool shed on Powell and 94th ave should have something. Call them first.

Good thought... no answer on the phone today (Labor Day), but I can check with them tomorrow.

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- '79 240D - engine swap complete! Engine broken in! 28-31 mpg! Lovin' the ride!
- '86 190D (W201-126) - 2.5 NA engine, 5 speed, cloth interior, manual climate controls, 33-34 mpg (sold to forum member).

I found a 46mm Hex bolt at a local hardware store and nut to fit it. Took it across the street to my neighbor Bob who welded the pieces together. So now I just use a regular ratchet on the welded-on nut to turn the whole thing! Worked like a charm!

What's the socket size for the fuel sender?

I remember pulling that out with just channel locks. It was comfortably sitting in there too.

Get some penetrating oil on that too. Don't want to strip out or break anything on that fuel tank

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-Typos courtesy of my mobile phone.

yeah something isn't right. I got mine off my 300D when I had it with channel locks and barely any synthetic elbow grease.

46mm

Ha, more good advice that I should have thought of last night, though it was after 9pm... at least I didn't go after it with a propane torch!

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- '79 240D - engine swap complete! Engine broken in! 28-31 mpg! Lovin' the ride!
- '86 190D (W201-126) - 2.5 NA engine, 5 speed, cloth interior, manual climate controls, 33-34 mpg (sold to forum member).

Yeah give it another go. Just have a good plastic bag to put it in so you dont get diesel everywhere

I gotta second the starton and reversing the fuel hoses idea. it is fine, and it'll clean out the tank very nicely. of course you will have to fill the tank first... and keep it above 1/2 tank for a few weeks...