Hey folks,

Just parked the old '77 240D today and opened the hood to see lots of diesel all over the driver's side of the motor. Long story short, the return line on #3 was split at the end and washing off the side of the motor.

I have some 3mm ID line for my '99 E300 that I was going to use to use to patch it together. Is this the proper size or do I need to get something different?

Thanks in advance.

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2013 Volkswagen Jetta Hybrid SEL Premium (Sparky)
http://badges.fuelly.com/images/smallsig-us/193500.png

It's a car not a science experiment! Open the throttle!

The size for the 240D is 3.2mm.
However, go to your favorite internet parts seller and compare the part number of the 240D Fuel Return Hose and the 99 E300 Return Hose. If the part numbera are the same they are the same size.

Otherwise the size for the 240D and alternative Hose Material choices and places to get it are somewhere below:
Repair Links
http://www.peachparts.com/shopforum/forumdisplay.php?f=82

http://www.peachparts.com/Wikka/DoItYourSelf

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84 300D, 82 Volvo 244Gl Diesel

I've seen weed eater fuel hose used in a bind.

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Jim

3.5mm is very close to 1/8"

FRACTION TO DECIMAL AND MM TABLE

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1985 300D 198K sold
1982 300D 202K
1989 300E 125K
1992 940T

"If you dont have time to do it safely, you dont have time to do it"

"The democracy will cease to exist when you take away from those who are willing to work and give to those who would not."

Looks like I was wrong; the stock size is 3.2mm not 3.5mm as I posted before.

More Notes: Authousaz has this info next to the Fuel Return Line: Fuel Hose/Line; 3.2mm ID x 1.9mm;
According to this site: Convert inches to mm - Conversion of Measurement Units
1/8"= 0.125"=3.175mm
So 1/8" ID Hose is actually a little tighter than the 3.2mm stock Hose.
Another company may have specs

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84 300D, 82 Volvo 244Gl Diesel

Tighter is gooder

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1985 300D 198K sold
1982 300D 202K
1989 300E 125K
1992 940T

"If you dont have time to do it safely, you dont have time to do it"

"The democracy will cease to exist when you take away from those who are willing to work and give to those who would not."

LOL.


Be sure to also consider: Fluoroelastomer Hose Grade A [hose1] | DudaDiesel Biodiesel Supplies

2.50/foot and should outlast standard rubber hose. 5' should be plenty.

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83 300TD (need rear wiper assembly dead or alive)
84 300SD Daily driver
85 300TD almost 400k miles and driven daily.
98 E300D *sold
86 300SDL *sold and made flawless 10 hour journey to new home.

Sure will be enough. I had left over from a 1 meter length.

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1985 300D 198K sold
1982 300D 202K
1989 300E 125K
1992 940T

"If you dont have time to do it safely, you dont have time to do it"

"The democracy will cease to exist when you take away from those who are willing to work and give to those who would not."

I just use 1/8" fuel line from NAPA

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1977 300D Lost coolant while someone else was driving
1983 300D Can't run without oil
1985 300SD (gone but not forgotten)
1990 300TE 4matic Sold
1991 Yamaha Venture
1975 Kawsaki 250 triple
1974 Honda 200CL
1951 8N Ford
2008 Wildfire 650C

NAPA also sells the real return line.

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84 300D, 82 Volvo 244Gl Diesel

Maybe in Long Beach but sure not in my neck of the woods. He wasnt even sure if he had any 1/4" left !

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1985 300D 198K sold
1982 300D 202K
1989 300E 125K
1992 940T

"If you dont have time to do it safely, you dont have time to do it"

"The democracy will cease to exist when you take away from those who are willing to work and give to those who would not."

Well, I have never bought any from NAPA. They have it on NAPA online so I assumed it was something that they could get.
Also VW and Volvo Diesels use it and maybe some others I do know about.

Also my way of doing things is different. I bought at least 25 Feet of return line and keep some in my Trunk.
My Volvo also uses the same Return Line.

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84 300D, 82 Volvo 244Gl Diesel

Makes sense. I was of course trying to avoid shipping charges.

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1985 300D 198K sold
1982 300D 202K
1989 300E 125K
1992 940T

"If you dont have time to do it safely, you dont have time to do it"

"The democracy will cease to exist when you take away from those who are willing to work and give to those who would not."

Thanks everyone.

I'm using the return hose that I purchased for the OM606. That way, I only need to stock one type of fuel return hose.

I'm going to pre-cut several pieces and keep them in a ziploc in the trunk for emergencies. Probably a couple of end caps as well.

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2013 Volkswagen Jetta Hybrid SEL Premium (Sparky)
http://badges.fuelly.com/images/smallsig-us/193500.png

It's a car not a science experiment! Open the throttle!

The NAPA guy here in town has the return hose, but since he get`s on my case for ordering MB parts on line, and not from him. he is off my list.
How ever, right across the street is a VW performance shop, and they carry the propper German Braded return hose.

I also carry some in a Zip lock bag in the trunk. I just keep 3 ft in one piece, and cut as needed when out on the road. also keep a pair of Dykes, needle nose plires and a genuine Bosch 24mm open end wrench for the fuel filter, in a seperate freezer zip lock. hand full of various light bulbs in one bag and several Nitrile gloves in another bag. these seperate bags are in a larger 10X10" zip lock to keep it all together, clean and dry.

Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works