The fuel supply line, return line & vent lines are all under the tank. There are rubber lines connected to the tubes coming out of the tank that are connected to steel lines using hose clamps. The steel lines run over the rear subframe along with the steel brake line coming to the rear wheels from the master cylinder. This is usually where the lines rust through and leak. Another place they tend to rust badly is where they pass through rubber supprt mounts that are metal bracketed to the floor pan under the vehicle. Replacement tubing in the proper diameter is available at most auto supply places and can be had in various lengths or in 25 foot coils. It is pretty easily formed by hand but I used a tubing bender to duplicate the bends in the original lines when I replaced them in my 1983 300D this winter. Although the brake line was not leaking I also replaced it as it was pretty badly rusted over the subframe where the fuel leak was. If you are replacing the brake line also you will need a flaring tool that can form an inverted or bubble flare to connect the lines to the master cylinder and the tee at the rear frame where the single line coming back from the master cylinder is divided into the lines that run to each rear brake caliper. The cheap AutoZone rental flaring tool didn't do an acceptable job for me so I ended up purchasing a very good flaring tool. Unless you have use for one I would try to have it done by a shop or borrow a tool. (This is for the brake line only.) If you have to do the brake line look carefully at the formed ends. The bubble flare is different than the single or double flare used on most other vehicles and the other types of flare are incompatible with bubble flare connections on the Mercedes master cylinder and tee block at the rear. The job wasn't very difficult. Just try to get the bends as close as possible to the original and be patient snaking the formed lines into the engine compartment & over the rear subframe. Using two lengths of fuel line & splicing them together would make the job easier.
Blaise
From: griegiry <newdlhead@aol.com>
To: diesel_mercedes@yahoogroups.com
Sent: Mon, July 18, 2011 4:28:20 AM
Subject: [diesel_mercedes] Re: replacing fuel lines on the 300sdl
thanks bobby, i gather you are talking about the injector overflow lines? i believe this fellow means the tank to engine lines. and that she leaks under the trunk. but that he was told the tank is not bad. i gather i have to get to the top of the tank to disconnect the fuel line from the sender, or does she have a spout out her side? i vaguely remember an article where a tank was removed from an sd to facilitate a greasecar kit, does not look like a job for the faint of heart.
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