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PointedThree :  Vans, Trucks, SUVs and Other Forums : G-Class : 1995 G320 Fuel Leak -- Bad fuel hose !!

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1995 G320 Fuel Leak -- Bad fuel hose !!
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Posted 9/17/2018 4:25 PM
gerryvz
Extreme Veteran




Date registered: Apr 2014
Location: Annapolis, MD
Vehicle(s): 1994 G320, 1989 560SEC, 1994 E500 (W124)
Posts: 336
300
1995 G320 Fuel Leak -- Bad fuel hose !!

Recently had a very strong smell of gasoline from the rear of my 1995 G320.  Some observation showed gasoline dripping down from the top of the plastic fuel tank onto the ground, with a very steady drip-drip-drip.  Tank was totally full.

After some research here, I pulled the fuel sender cover (four screws) under the rear deck carpeting.  Though the area looked pretty crusty, and the vent hoses attached to the top of the tank were slightly cracked on the ends, nothing looked wet or amiss in the area.

More investigation showed that the leak was only happening with the engine running, eliminating the tank itself as a source for the leak.  Eventually saw that there was gas dripping from the inside frame rail down onto the tank. Removed the curved black plastic driver's side inner fender lining and saw the culprit -- a three-pronged "spray" of gasoline out the side of the curved fuel hose that connects the output of the fuel filter (sitting in its bracket) to the hard fuel supply line that goes forward to the engine.

So, I found the culprit.  I ordered all new lines (four of them) that supply the tank to the pump, and the pump to the filter, and the filter to the supply line.  I'll also change the filter at the same time, as it's got 30+K miles on it and I don't know when it was last done. Haven't been driving the G after I noticed the leak.

I'll take photos and do a HOW-TO article on replacement of the hoses.  

Word to folks -- if your G is 20+ years old and you are still on your original fuel lines, it behooves you to replace them both at the tank end, and inside the engine compartment where they feed the engine.  You early MBUSA G-owners aren't necessarily exempt from the curse of old/hardened rubber, either....

Fortunately all of the lines I ordered are still available from MB.  The lines I ordered are

Part Number    Part Name    Price    Quantity    Total
463-470-01-75    Fuel Hose    $51.80    1    $51.80
463-470-02-75    Fuel Hose    $71.78    1    $71.78
463-470-03-75    Fuel Hose    $88.06    1    $88.06
463-470-00-75    Fuel Hose    $85.10    1    $85.10

Just under $300 for the four lines, no sales tax and sold via www.mboemparts.com with free shipping using my web site's special promo code at checkout, 500EPROMO.

Next up will be the engine compartment and the tank vent lines.  Those G320 owners with M112 engines have some aftermarket (Cohline) options, as a couple of the hoses were shared with other chassis (sedans/coupes).  For M104 owners, all of the lines were W463-proprietary.

Cheers,

Gerry

#239842
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Author
Posted 9/17/2018 10:22 PM
AlanMcR
Expert




Date registered: Apr 2006
Location: US, CA, Los Altos
Vehicle(s): G300DT E300DT 230SL
Posts: 3500
2000
RE: 1995 G320 Fuel Leak -- Bad fuel hose !!

If you haven't replaced the fuel filter, do it now.  A severely plugged fuel filter can back up enough pressure to cause problems.  I was nearly immolated in my old Montero by a filter that plugged and split open.  Fortunately it sprayed away from the catalytic converter, and not at it.
#239848 - in reply to #239842
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Author
Posted 9/18/2018 8:36 AM
gerryvz
Extreme Veteran




Date registered: Apr 2014
Location: Annapolis, MD
Vehicle(s): 1994 G320, 1989 560SEC, 1994 E500 (W124)
Posts: 336
300
Re: 1995 G320 Fuel Leak -- Bad fuel hose !!

Good advise and yes I've got a new Hengst (my preferred brand) filter on order. For the 104-based G-wagens, the filter is a common one (MB part number 002 477 45 01 is current number, former number 002 477 06 01) that is used on a number of various 1990s S- and C-class models.
#239850 - in reply to #239842
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Author
Posted 9/28/2018 8:56 PM
gerryvz
Extreme Veteran




Date registered: Apr 2014
Location: Annapolis, MD
Vehicle(s): 1994 G320, 1989 560SEC, 1994 E500 (W124)
Posts: 336
300
Re: 1995 G320 Fuel Leak -- Bad fuel hose !!

I’ve been advised that 463 470 00 75 is NLA from MB.

Part 463 470 01 75 is on back order but expected to come available again.

02 75 and 03 75 are both available and shipping to me.

Guess I need to find substitutes for the unobtanium hoses. Need to measure them and see if there are any car hoses that can be adapted.
#239873 - in reply to #239842
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Author
Posted 9/29/2018 9:50 PM
DesertStar
Expert




Date registered: Apr 2006
Location: San Diego, CA USA
Vehicle(s): 85-280GE/95-G320/08-G500
Posts: 2156
2000
Re: 1995 G320 Fuel Leak -- Bad fuel hose !!

Exact same thing happened to me 2 years ago in Palm Springs. Always interesting how same vehicles have similar problems at around the same times/mileage. i thought i posted my ordeal as well but cant find it.  My leak was the cigar hose that was a different size at each end going from hard line to tank fuel return..

Edited by DesertStar 9/29/2018 10:06 PM
#239878 - in reply to #239842
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Author
Posted 10/11/2018 6:15 PM
gerryvz
Extreme Veteran




Date registered: Apr 2014
Location: Annapolis, MD
Vehicle(s): 1994 G320, 1989 560SEC, 1994 E500 (W124)
Posts: 336
300
Re: 1995 G320 Fuel Leak -- Bad fuel hose !!

I received the two hoses from MB that go from the fuel pump INTO the fuel filter (one end is a screw end and the other end is a banjo fitting), and the hose that goes from the fuel filter to the supply line under the truck.

That second line (02 75), unfortunately, came with the correct "screw end" to connect to the supply line, but the other end of the hose had nothing attached. The line that I removed from the truck had a bent-metal end where it connected to the fuel filter.

I took the old (leaking) hose and the new hose (sans bent metal fitting) to a local hydraulic hose shop that specializes in making hoses.

They are either going to remove and re-use the crimped bent-metal fitting and attach it to the end of the new hose, or they will create a new bent-metal fitting. There was some surface rust on the bent-metal fitting, although they felt it was fully functional and would clean up OK.

Guess I'll see in a few days when they get back to me. I'll replace the filter and both lines to it.

It looks like the fuel pump is located under the trunk nestled under the tank and under the metal skid plate, so I'll remove that and inspect the pump and lines there as well. Likely candidates for replacement, as well as the two lines in the engine compartment that lead to the engine from the hard lines under the truck.
#239917 - in reply to #239842
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Posted 10/13/2018 3:37 PM
DesertStar
Expert




Date registered: Apr 2006
Location: San Diego, CA USA
Vehicle(s): 85-280GE/95-G320/08-G500
Posts: 2156
2000
Re: 1995 G320 Fuel Leak -- Bad fuel hose !!

Actually the hose I had a problem with was a461 476 02 26. Different diameter on each end and connects to fuel tank and fuel return line.

Another person on another forum had same problem here and posted photos:

http://www.viermalvier.de/ubbthreads.php/topics/622703/all/Benzindu...
#239927 - in reply to #239917
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Posted 10/14/2018 11:34 AM
gerryvz
Extreme Veteran




Date registered: Apr 2014
Location: Annapolis, MD
Vehicle(s): 1994 G320, 1989 560SEC, 1994 E500 (W124)
Posts: 336
300
Re: 1995 G320 Fuel Leak -- Bad fuel hose !!

Yes, I am substituting an "available" hose (having a fitting put on the end of it) for a non-available one.

Also, some research I've been doing shows that perhaps a 280GE fuel injection hose may be able to substitute for the NLA hose with the "u" shaped metal fitting coming off the engine side of the fuel filter. I'm going to order one of those 280GE hoses and see if it works, in addition to the hose I'm having made.
#239929 - in reply to #239842
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Posted 10/18/2018 2:42 PM
gerryvz
Extreme Veteran




Date registered: Apr 2014
Location: Annapolis, MD
Vehicle(s): 1994 G320, 1989 560SEC, 1994 E500 (W124)
Posts: 336
300
Re: 1995 G320 Fuel Leak -- Bad fuel hose !!

I got the hose back from the hose shop today. They matched the bent-metal "U" fitting exactly, and it is quite nice. I paid $48 including tax for the hose - quite steep for just sourcing, bending and crimping on a fitting to an existing hose. That said, it is a factory MB hose and of the correct diameter.

A test fit of the bent end to the fuel filter outlet shows that it is a good fit.

I will get under the truck tonight and replace the fuel filter and hose.
#239947 - in reply to #239842
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Posted 12/30/2018 5:10 PM
gerryvz
Extreme Veteran




Date registered: Apr 2014
Location: Annapolis, MD
Vehicle(s): 1994 G320, 1989 560SEC, 1994 E500 (W124)
Posts: 336
300
Re: 1995 G320 Fuel Leak -- Bad fuel hose !!

gerryvz - 10/18/2018 1:42 PM I got the hose back from the hose shop today. They matched the bent-metal "U" fitting exactly, and it is quite nice. I paid $48 including tax for the hose - quite steep for just sourcing, bending and crimping on a fitting to an existing hose. That said, it is a factory MB hose and of the correct diameter. A test fit of the bent end to the fuel filter outlet shows that it is a good fit. I will get under the truck tonight and replace the fuel filter and hose.
I replaced the leaking hose a couple of days after getting the hose back from the local shop, to get the trunk up and running again. I never replaced the inner wheel well lining in anticipation of replacing the other fuel line going from the fuel pump into the fuel filter, and replacing the fuel filter itself.

Today I finally did that task, and it went pretty seamlessly. Having a set of flare line wrenches (for additional leverage on the fuel hose fittings) was a real bonus -- I recommend getting a set for fuel and brake line work, and not chancing it with "regular" wrenches when possible.

Have attached a couple of photos of the replaced fuel lines and fuel filter.

Cheers,
Gerrhy





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#240290 - in reply to #239947
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