G320 (M104 motor) Fuel Hose Replacement

[gerryvz]

Recently, one of the fuel lines on my 1995 G320 sprung a leak, necessitating its replacement. For that matter, necessitating the replacement of ALL of the fuel hoses. As far as I can tell, all lines are original.

(all photos and illustrations in this thread are from Mike C. of the PointedThree forum)

Below is the EPC diagram of the G320 and G36 AMG fuel line system, as provided by Mike C., a friendly & knowledgable Pointed-Three G-wagen owner:



Note that the fuel flows from fuel tank to fuel pump, then to the fuel filter, then to the engine, in that order.

To start off, I ordered from MB four fuel lines:

463 470 00 75 -- feed line that goes from the fuel tank to the fuel pump inlet

463 470 01 75 -- line from outlet of fuel filter to hard line under truck that feeds engine

463 470 02 75 -- second line that goes from fuel pump to fuel filter inlet (banjo fitting on fuel filter end)

463 470 03 75 -- first line that connects directly from fuel pump outlet to fuel filter

What I found is that:

• the 00 75 line is NLA from MB, and will never be available again
• the 01 75 line is currently backordered from MB, with no availability date projected
• the 02 75 and 03 75 lines are available from MB, and I received them

The line that sprung the leak was the line that leads from the fuel filter OUTLET to the hard line that goes under the truck to supply the engine -- 463 470 01 75. This line has an ordinary "screw" fitting on one end, and a curved "U-shaped" metal end that screws onto the fuel filter outlet.

What I found was at the 03 75 hose is exactly the same length as the 01 75 hose, and ships from the factory with the screw fitting already crimped onto one end (see image below) with nothing on the other end.

I removed the leaky 01 75 hose from my G-wagen, and brought both it and the new 03 75 hose to a local company that does fuel and hydraulic hoses. They agreed to either re-use the metal "U-shaped" fitting from my existing 01 75 hose and crimp it onto the new 03 75 hose, or they would create a new U-shaped metal fitting if needed and crimp it on the new hose.

Here are a couple of views of the back-ordered 01 75 hose (with the U-shaped metal fitting) on the truck, mounted to the fuel filter on the right side of the photo. The hose on the left side is the 02 75 hose, which has the banjo fitting on it as mentioned, connecting to the fuel filter inlet.



As part of this project, I aim to replace all of the fuel lines both in the rear of the truck, as well as those underhood. Thus, as part of this project, I will be doing the following:

• re-ordering ANOTHER 03 75 hose, to replace the new one I bought as the donor for the back-ordered 01 75 hose
• replacing the 02 75 hose (with the banjo end) that goes into the fuel filter
• manufacturing or substituting a hose for the 00 75 hose that goes from tank to fuel pump
• replacing another hose under the truck, 463 476 14 26, which is a short hose in the feed line from the fuel filter to the engine feed. Fortunately this hose is still available from MB, though it is also easily substitutable from other car models and chassis
• replacing both the supply and return lines under the hood, which go from the hard lines under the truck to/from the M104 fuel rail & fuel cooler. These hoses are part numbers 463 470 07 75 and 463 4670 10 75 (both return lines), and feed line 463 476 14 26. Also 461 476 02 26, which runs from the fuel return hard line under the truck to the fuel tank
• Replace the fuel filter (which I already have in hand)

Doing some research, it also appears that there is a 280GE (M110, CIS) fuel hose that could potentially substitute for the back-ordered 463 470 01 75 hose. Its metal "U" fitting is more of an "L" shape, but it appears that it could work. I plan to order one of these to see if it will work correctly as a substitute.

All for now -- I'll report more back as I learn it, and will do a fuel hose replacement HOW-TO once that operation commences.

Cheers,
Gerry

 

[gsxr]

Recently, one of the fuel lines on my 1995 G320 sprung a leak, necessitating its replacement.

What I found is that:

• the 00 75 line is NLA from MB, and will never be available again
• the 01 75 line is currently backordered from MB, with no availability date projected
• the 02 75 and 03 75 lines are available from MB, and I received them

What is with MB refusing to produce mission-critical parts? There have to be a zillion G's on the road that use these hoses.

 

[gerryvz]

I have not cross-referenced with other models, but I think some of these hoses may be specific to the M104-based G. I need to do the cross-ref.

 

[gerryvz]

A few more images of the hoses in question:

463 470 00 75 (NLA from MB) -- fuel tank to fuel pump



463 470 01 75 (supposedly on back-order from MB) -- fuel filter outlet to feed line



463 470 02 75 (available; in my possession) -- fuel pump outlet to fuel filter inlet



463 470 03 75 (available from MB; being made into a 01 75 hose) -- fuel filter outlet to feed line



463 476 14 26 (available from MB) -- fuel feed line to MB fuel cooler

 

[nocfn]

I have not cross-referenced with other models, but I think some of these hoses may be specific to the M104-based G. I need to do the cross-ref.

May have to remove the shield and use
Bulk hose on the barbs.

 

[gerryvz]

It won’t be particularly difficult to get proper hoses made, or to substitute hoses from other models if needed.

 

[gerryvz]

Together, Mike and I have been able to come up with some alternatives to the NLA hoses, so I've put in an order for a few hoses.

For the back-ordered 0175 hose, which has the "u-shaped" metal fitting that goes from the fuel filter outlet to the fuel feed hard line under the truck, we found the following hose, 124 470 80 75. This is made by both MB and Cohline (the OEM for MB), and it's about 15% the price as a Cohline-branded hose than the MB line is. This 124 470 80 75 hose looks like this:




Another hose, which goes from the end of the hard feed line to the engine on the engine (front) side of the truck, 463 470 14 26, appears that it can be also substituted with 116 470 27 75. This line is shown below:




I also ordered the following line, which also looks like it can be used as a possible substitute for the 0175 (back-ordered) fuel line. This is a 126 line that goes to the fuel cooler on the 560SEL/SEC etc.




Still a number of hoses that need replacing, and several of them (particularly ones underhood) are looking like they are NLA from MB.

I did two-day shipping on my order so that I can get the truck back up and running. I know y'all are waiting for the inevitable HOW-TO.....

Cheers,
Gerry

 

[M104-AMG]

FWIW, I had a local hydraulic supply make me new fuel and self-levelling lines by re-using then ends. Update the fuel-lines to a more ethanol-friendly line with more reinforcements for longer durability. It was very inexpensive.

neil

 

[gsxr]

Gerry, the 124-470-80-75 hose is unlikely to have Cohline rubber. Aftermarket OEM went NLA a few years ago... unless they've come back into production? Last "OEM" hose I got a few years ago was Trucktec, with the Trucktec logo covered in black magic marker.

Details & photos are at this thread:
https://www.500eboard.com/forums/showthread.php?t=8977&p=118783&viewfull=1#post118783

If you order Cohline and get a real Cohline hose, please post photos!! I find it suspicious that FCP does not list any country of origin for the Cohline hose, and also does not list it as 'OEM' either...
https://www.fcpeuro.com/products/mercedes-fuel-hose-fuel-filter-to-fuel-feed-line-cohline-1244708075

Since this hose can cause a car-b-que if it fails, I've been shelling out the outrageous price for OE.

 

[gerryvz]

I’ll let you know what I get. If it’s crap, I won’t use it. Mainly I care about fit, as a backup/alternative to the one I’m having made.

If it fits, then I will likely order one as a spare.

If it’s Trucktek, I’ll use the one I’m having made/refurbished. And I’ll throw it as far as I can — maybe it will land in ntrepid’s or 8899’s yard.

One sniff should tell me for sure.

 

[gerryvz]

Today I received the new hose from the local hose shop. They decided to create a new metal fitting for the fuel filter outlet end of the hose, rather than trying to re-use the old fitting. They did create, bend and crimp the new fitting onto the end of the MB hose 463 470 03 75, so I will need to re-order a new hose for that application.

The cost of the "new" hose was $48 including tax -- not super cheap.

Here are some views of the old (leaking) hose and the new fitting. You can see the cracks in the bend in the old hose -- these are where the gasoline mist was spraying out of against the frame of the truck. The molded angle-bend in the new hose will straighten itself out once it is mounted. I plan to fit the new hose and replacement fuel filter tonight onto the truck.

You can see the poor condition of the old fuel line. The truck has less than 130,000 miles on it, so this is largely caused by the age of the rubber, not necessarily use. If you have not replaced the fuel lines in your E500E, remember that these lines are actually one year NEWER than the newest E500 out there, the truck being a 1995 model.

REPLACE YOUR FUEL LINES......

 

[gerryvz]

Installed the new hose without replacing the fuel filter. All matched up nicely and was able to drive the G for the first time in about a month tonight. I'll tackle the fuel filter and line replacement tomorrow or perhaps Saturday morning before we head over to tailgate at the Navy football game....

 

[gerryvz]

Gerry, the 124-470-80-75 hose is unlikely to have Cohline rubber. Aftermarket OEM went NLA a few years ago... unless they've come back into production? Last "OEM" hose I got a few years ago was Trucktec, with the Trucktec logo covered in black magic marker.

Details & photos are at this thread:
https://www.500eboard.com/forums/showthread.php?t=8977&p=118783&viewfull=1#post118783

If you order Cohline and get a real Cohline hose, please post photos!! I find it suspicious that FCP does not list any country of origin for the Cohline hose, and also does not list it as 'OEM' either...
https://www.fcpeuro.com/products/mercedes-fuel-hose-fuel-filter-to-fuel-feed-line-cohline-1244708075

Since this hose can cause a car-b-que if it fails, I've been shelling out the outrageous price for OE.

Dave,

I received the hose today, 124 470 80 75. It is, indeed, a Cohline hose that was made in Germany. I've attached photos for proof. I recommend, since this is a part that all E500E owners need, that they should get this part as soon as possible in case it goes out of stock again. I purchased this hose from AutohauZ, FYI, not FCP.

For my G320 application, it appears that this hose is about a foot too long, but it will certainly still work in this application. Since I have the hose that the local company made already in hand and installed on the truck, I think I'll use this Cohline hose for the E500.

Cheers,
Gerry

 

[gerryvz]

Recently, one of the fuel lines on my 1995 G320 sprung a leak, necessitating its replacement. For that matter, necessitating the replacement of ALL of the fuel hoses. As far as I can tell, all lines are original.

(all photos and illustrations in this thread are from Mike C. of the PointedThree forum)

Below is the EPC diagram of the G320 and G36 AMG fuel line system, as provided by Mike C., a friendly & knowledgable Pointed-Three G-wagen owner:

View attachment 73178

Note that the fuel flows from fuel tank to fuel pump, then to the fuel filter, then to the engine, in that order.

To start off, I ordered from MB four fuel lines:

463 470 00 75 -- feed line that goes from the fuel tank to the fuel pump inlet

463 470 01 75 -- line from outlet of fuel filter to hard line under truck that feeds engine

463 470 02 75 -- second line that goes from fuel pump to fuel filter inlet (banjo fitting on fuel filter end)

463 470 03 75 -- first line that connects directly from fuel pump outlet to fuel filter

What I found is that:

• the 00 75 line is NLA from MB, and will never be available again
• the 01 75 line is currently backordered from MB, with no availability date projected
• the 02 75 and 03 75 lines are available from MB, and I received them

I am being told that the 463 470 00 75 hose is now again available from MB, for a list price of $112 (discounted to ~$80).

The 463 470 01 75 hose has been discontinued by MB.

The 463 470 02 75 and 03 75 hoses are still available from MB.

 

[jftu105]

Recently smelled gasoline while driving of my E320, 1995, special edition. Opened up the hood, sure enough, one of the two fuel line hoses ballooned up at one spot. If it bursts, it could start a fire. Unfortunately, I could not find any hoses off those typical MB online stores.

At the end, I went to junkyard. I sourced many similar hoses out of newer MBs, most C-class, with stainless steel braids outside. There are so many different lengths and shapes. Connectors are the same but they could be oriented in different directions. I managed to find 4 hoses which would fit M104 engines out of perhaps 10 newer MB in the yard.

Replaced both hose lines and the smell is gone. With new parts becoming less available and rarely any cars in the yard, it is getting tougher to keep the car going. No electric cars for me as I would like to save our environment by preventing digging bigger and bigger holes in the mountains to hunt down lithium.

Keep your currently cars running in good condition is the greenest of all.

jftu105

 

[gsxr]

Recently smelled gasoline while driving of my E320, 1995, special edition. Opened up the hood, sure enough, one of the two fuel line hoses ballooned up at one spot. If it bursts, it could start a fire. Unfortunately, I could not find any hoses off those typical MB online stores.

At the end, I went to junkyard. I sourced many similar hoses out of newer MBs, most C-class, with stainless steel braids outside. There are so many different lengths and shapes. Connectors are the same but they could be oriented in different directions. I managed to find 4 hoses which would fit M104 engines out of perhaps 10 newer MB in the yard.

Keep in mind your replacement hoses are still 25-30 years old and could have a similar failure. When possible, new hoses are highly recommended. Looking up the 124.032 in the EPC, there should be 2 hoses. A1244706775 and A1244707975.

A1244706775 appears to still be available new from dealers for ~$25 (with a -64 suffix, indicating a different supplier than previously). Aftermarket is OOS everywhere.

A1244707975 is possibly NLA from MB, but had been ~$50 or so. You'd have to call a dealership and ask a live person to check worldwide inventory. (Update March 2024: This hose shows NLA at both MB Classic (link) and RevParts dealers online.)

If you saved the old hose, it should be possible for a hydraulic shop to rebuild them with fresh hose and re-use the metal ends. I'd strongly suggest you do this and replace the junkyard hoses with rebuilt. If a hose lets go on the freeway and starts spraying gas under the hood, by the time you know what's happening you Special Edition will be a Car-B-Que.

 

[jftu105]

Dave,

Thanks for the information. I searched hard but could not find them anywhere before I went the yard route. I can't even find them on eBay.

If you have a link to any of these two hoses, let me know. Thanks in advance.

In fact, these two hoses are very similar, with one slightly longer than the other. The longer one can substitute in for the short one.

The ones I sourced from the yard were from C-class, likely around 2010. Newer MB all used hoses with stainless steel braid. It probably helps to keep the rubber temperature lower to last longer but you cannot see the rubber condition anymore.

My local MB dealer is very hard to work with.

jftu105

 

[jftu105]

This is one of the fuel hoses I sourced out of a yard. I found this one is about 14" long, a bit too short for E320, 1994-5.

The car model is Mercedes Benz W203 C180 Fuel Injection pipe A2034700575 2004-2011.

I also found 2010-2013 C class or 2011 E350 fuel hoses would work, but somehow, I simply cannot find a store to buy them.

This is P/N 2044700675 for the hose below, which is about 16" long, which works great. When I go to AutohousAz or FCP with the following car models, I still could not find these hoses.

A2114701575 also works great.



A2304702475, might be a bit short, also around 14"




jftu105

 

[gsxr]

A1244706775 appears to be available at US dealers. Pick your favorite RevParts vendor... Naperville, Laredo, Annapolis, etc:

Fuel Hose 124-470-67-75-64 | MB OEM Parts

124-470-67-75-64 - Fuel Hose

www.mboemparts.com

Factory Direct OEM Fuel Hose Part# 124-470-67-75-64 Fits MB Parts Source

124-470-67-75-64 - Fuel Hose

www.mbpartsource.com

The W203 hose A2034700575 is slightly cheaper. Note this one also has a -64 suffix. I wonder if it still has the stainless braid for $18:

Fuel Hose 203-470-22-75-64 | MB OEM Parts

203-470-22-75-64 - Fuel Hose

www.mboemparts.com

Factory Direct OEM Fuel Hose Part# 203-470-22-75-64 Fits MB Parts Source

203-470-22-75-64 - Fuel Hose

www.mbpartsource.com

 

[jftu105]

I am being told that the 463 470 00 75 hose is now again available from MB, for a list price of $112 (discounted to ~$80).

The 463 470 01 75 hose has been discontinued by MB.

The 463 470 02 75 and 03 75 hoses are still available from MB.

It is more like 15 years old as they are for 2010ish C-class. My problem is that I could not find anywhere to buy the new hoses. Forget my local MB dealer. There is no magic bullet, MB or not, with the rubber hose. All rubber hoses are subject to failures. Just need to keep eyes on them, new or used, MB or not.

jftu105

 

[gerryvz]

I am being told that the 463 470 00 75 hose is now again available from MB, for a list price of $112 (discounted to ~$80).

The 463 470 01 75 hose has been discontinued by MB.

The 463 470 02 75 and 03 75 hoses are still available from MB.

It appears that both the 463 470 00 75 and the 463 470 01 75 hoses are (again) available from MB. I am going to place orders for both of them and see what comes back.

 

[jftu105]

Anyway to reduce the shipping cost? $72 for shipping for five fuel hoses.

Thanks.

jftu105

 

[geraniumtr]

jftu105, you might want to look at another retailer. I use MBpartsource.com which is MB of Laredo. Very competitive prices and reasonable shipping charges. I've always had a good experience with these guys. Their default MB warehouse is also in Texas so parts delivery is very prompt.

Regards,


Peter Weissman

 

[gsxr]

Anyway to reduce the shipping cost? $72 for shipping for five fuel hoses.

Find another dollar to add to the order and you get FREE shipping with code 500EPROMO, minimum $100 order. It's the shopping cart calculator that is coming up with silly ship estimates.

Laredo is another good option with pretty reasonable S&H fees, although usually Napsterville will beat the total after you factor in free shipping.

 

[jftu105]

Thanks for the suggestions. Just tried and put in 500EPROMO, but it says, NOT VALID.

 

[gsxr]

Thanks for the suggestions. Just tried and put in 500EPROMO, but it says, NOT VALID.

Verify you are at MBOEMParts.com and not a different vendor. Their price for p/n 203-470-22-75-64 is $18.53 each, not $18.45...

Fuel Hose 203-470-22-75-64 | MB OEM Parts

203-470-22-75-64 - Fuel Hose

www.mboemparts.com

 

[jftu105]

YES! It worked! Thanks a million (and one hundred dollars). Just placed an order of 4 hoses of 124-47--6775-64 and 2 hoses for 203-470-2275-64. Free shipping, a grand total of $126 for six genuine MB hoses. Hard to beat such price in face of major inflation we have.

Dave is THE BEST!!!

jftu105

 

[jftu105]

Received an email from MBoemparts.com today as follows, telling me that the fuel hoses I ordered need to ship from Germany. These hoses are really becoming hard to find. I am stocking up and told them I would wait. The shipping alone from Germany is more than what I paid for them.

---------------------------------​

Hello,​

​

Both parts ordered are coming from Germany and will take 11-12 business days to arrive. Would you like to continue with the order and wait for them to arrive?​

​

If not, we can refund the complete order.​

​

Thanks.​

---------------------------------​

Did some little maintenance for an E320, 1994 of a friend and noticed one of his fuel hoses badly ballooned up. He said he never smelled gasoline. Replaced both with the ones I collected from the yard off C-class sedans. I don't have any spare left; thus, the need to stock up. Of course, his cabin filter was moldy and filthy, over 3-4 years old. Now, I rebuild cabin filters with active carbon sheets from eBay. I cover the filter with a piece of blue shop towel paper as the pre-filter.

Dirty cabin filters could be a source of virus infection. Before placing the "new" filter in, I typically use a ozone generator (made in Canada), placed at the air intake near the windshield with and the AC circulation fan on, to bombard the entire AC passages and the evaporator with ozone. The ozone then enters the cabin and exits through a gap I leave at the rear windows. I let it run for about 20 to 30 minutes, hoping to kill the germs in all the air ducts as well as inside the cabin.

The car smells much fresher afterward.

Cars age, people age, while parts become hard to find. At some point, bicycles are the ones left as reliable transportation tools.


jftu105

 

[rayhennig]

My pumps are to be replaced soon so I looked for A1244706975, A1244703775 and A1244708075. A total of 600€ from MB. For a few pipes.

Two of them are available from Trucktec for around 30€ each. I hear bad things about Trucktec. So, I am tempted to buy the Trucktecs and then get our local agri machinary guy to replicate them with quality parts.

What do you think of this plan?

RayH

 

[gsxr]

My pumps are to be replaced soon so I looked for A1244706975, A1244703775 and A1244708075. A total of 600€ from MB. For a few pipes.

The first & third hose are still available new from MB. $200 USD total for both, for Genuine MB in USA.

A1244703775 is showing NLA at MBCC:

Mercedes-Benz Classic Parts Search.

Browse through the Mercedes-Benz Classic Parts Search to see the availability of parts, promotional and newly manufactured parts and order them online (only in Germany).

partssearch.mercedes-benz-classic.com

Two of them are available from Trucktec for around 30€ each. I hear bad things about Trucktec. So, I am tempted to buy the Trucktecs and then get our local agri machinary guy to replicate them with quality parts.

What do you think of this plan?

For the 2 available new, buy Genuine MB. Buy once, cry once.

For the NLA hose A1244703775, assuming the existing hose is Genuine MB, I'd rebuild that instead if Trucktec. Depends if the local guy can replicate the metal ends/fittings or will just replace the rubber hose.

I assume Trucktec only supplies the 2 hoses that you can buy new Genuine MB for $200. Zero savings there. I also assume Trucktec does NOT supply the NLA hose shown below. There are some NOS available on eBay for ~$400 USD (link)... you missed one that sold a couple months ago for $120 USD.

 

[gerryvz]

Following up on the original premise of this post, I have decided to replace all fuel lines on the G320. This is starting with the fuel ventilation system lines attached to the fuel tank, as a starting point. I am starting with this, because an inspection of these lines last year, indicated that several of them have cracks.

To that end, I recently ordered the following hoses and items:

• fuel pump - 003 091 53 01 ($125.00)
• fuel tank vent valve - 000 476 22 32 ($74.10)
• short line from fuel sender to breather line - 140mm - 916030 000526 ($26.65/meter)
• short line from top of tank to breather line - 463 476 50 26 ($37.25)
• line from breather line to filler neck - 560mm - 916030 000526 ($26.65/meter)
• line from top of tank to filler neck - 420mm - 916030 000526 ($26.65/meter)
• line from filler neck to vent valve first part - 125mm - 230 476 87 26 ($24.70/meter)
• line from filler neck to vent valve second part - 460 476 48 26 (NLA from MB) - purchased NOS hose from Australia
• line from vent valve to breather pipe - 460 476 36 26 ($20.80)
• line from vent valve, capped - 1060mm - 007 997 61 82 ($3.77/meter)

Next up (ordering next week) will be a replacement of other fuel lines and system components:

• short line from fuel tank to fuel pump - 463 470 00 75 - now available again ($100.10)
• line between fuel return hard line and fuel tank - 461 476 02 26 ($33.80) - 2 required
• line between fuel pump and fuel tank - 463 470 03 75 ($88.40)
• fuel feed line from feed hard line to engine - 463 476 14 26 (NLA from MB)
• fuel return line from engine to return hard line - 463 470 07 75 (NLA from MB)
• fuel line from fuel filter to fuel feed hard line - 463 470 01 75 ($55.25)
• fuel strainer - 463 470 03 06 ($156.00)
• fuel level sender - 009 542 67 17 ($157.30)

For the two NLA lines (which are the immediate feed and return lines that attach to the engine from the under-body hard lines), I will have to have them made up by a custom hose shop, supplying the original lines as models and hopefully providing MB fuel hose of the appropriate diameter that they can cut to length to create the new lines.

I am going to create a two-part HOW-TO on the replacement of the fuel ventilation system (Part I), and the replacement of the fuel delivery system (Part 2). This will entail removing the fuel tank, replacing the fuel pump, fuel strainer, and fuel sender from the tank, cleaning the tank, and then removing and replacing all hardware.

The fuel level sender is in good operating condition, so it will likely just be cleaned and re-installed. I will likely replace the fuel pump (retaining the original pump as an operating spare), and will replace the fuel strainer as a matter of course.

The fuel pump is the same part as the units that are used in the latest E500s employing the single fuel pump (I believe it's a Pierburg pump), as well as other later W124s such as the E320, as well as the SL600 and various 190Es.

 

[rayhennig]

Following up on the original premise of this post, I have decided to replace all fuel lines on the G320. This is starting with the fuel ventilation system lines attached to the fuel tank, as a starting point. I am starting with this, because an inspection of these lines last year, indicated that several of them have cracks.

To that end, I recently ordered the following hoses and items:

• fuel pump - 003 091 53 01 ($125.00)
• fuel tank vent valve - 000 476 22 32 ($74.10)
• short line from fuel sender to breather line - 140mm - 916030 000526 ($26.65/meter)
• short line from top of tank to breather line - 463 476 50 26 ($37.25)
• line from breather line to filler neck - 560mm - 916030 000526 ($26.65/meter)
• line from top of tank to filler neck - 420mm - 916030 000526 ($26.65/meter)
• line from filler neck to vent valve first part - 125mm - 230 476 87 26 ($24.70/meter)
• line from filler neck to vent valve second part - 460 476 48 26 (NLA from MB) - purchased NOS hose from Australia
• line from vent valve to breather pipe - 460 476 36 26 ($20.80)
• line from vent valve, capped - 1060mm - 007 997 61 82 ($3.77/meter)

Next up (ordering next week) will be a replacement of other fuel lines and system components:

• short line from fuel tank to fuel pump - 463 470 00 75 - now available again ($100.10)
• line between fuel return hard line and fuel tank - 461 476 02 26 ($33.80) - 2 required
• line between fuel pump and fuel tank - 463 470 03 75 ($88.40)
• fuel feed line from tank to engine - 463 476 14 26 (NLA from MB)
• fuel return line from engine to return hard line - 463 470 07 75 (NLA from MB)
• fuel line from fuel filter to fuel feed hard line - 463 470 01 75 $55.25)
• fuel strainer - 463 470 03 06 ($156.00)
• fuel level sender - 009 542 67 17 ($157.30)

For the two NLA lines (which are the immediate feed and return lines that attach to the engine from the under-body hard lines), I will have to have them made up by a custom hose shop, supplying the original lines as models and hopefully providing MB fuel hose of the appropriate diameter that they can cut to length to create the new lines.

I am going to create a two-part HOW-TO on the replacement of the fuel ventilation system (Part I), and the replacement of the fuel delivery system (Part 2). This will entail removing the fuel tank, replacing the fuel pump, fuel strainer, and fuel sender from the tank, cleaning the tank, and then removing and replacing all hardware.

The fuel level sender is in good operating condition, so it will likely just be cleaned and re-installed. I will likely replace the fuel pump (retaining the original pump as an operating spare), and will replace the fuel strainer as a matter of course.

The fuel pump is the same part as the units that are used in the latest E500s employing the single fuel pump (I believe it's a Pierburg pump), as well as other later W124s such as the E320, as well as the SL600 and various 190Es.

Quite a list of purchases.

My last remaining hose is over 300€ here in Europe but I spotted one in the US for about 140$ plus shipment making it around 170$. That would be a good saving but I'll doubtless be in for some import duty so it remains to be seen what the final bill will be.

The good news is that I'll then have a complete kit of MB original stuff from tank strainer to the output pipe. Then I'll enlist my man when the tank is close to empty.

Good luck with yours.

RayH

 

[gerryvz]

Quite a list of purchases.

My last remaining hose is over 300€ here in Europe but I spotted one in the US for about 140$ plus shipment making it around 170$. That would be a good saving but I'll doubtless be in for some import duty so it remains to be seen what the final bill will be.

The good news is that I'll then have a complete kit of MB original stuff from tank strainer to the output pipe. Then I'll enlist my man when the tank is close to empty.

Good luck with yours.

RayH

Thanks. I'm going to do the job when the tank is next empty, if I have all of the hoses in time. I have all of the ventilation system hoses in hand now. I'll order the fuel system hoses and other items next week.

The fuel tank is 3/4 full, so I probably have 2-3 weeks until it's empty and I can do the job with only a couple gallons in the tank. If I push it to the limits, I can JUST get 300 miles out of a tank of fuel.

Also, FYI, the rubber gasket that seals the fuel strainer to the tank is NLA from MB. I'm going to need to find a substitute for this piece of rubber. Perhaps a newer G-wagen model seal would do the trick, given that the fuel tank was used on all G-wagens until relatively recently.

 

[rayhennig]

Thanks. I'm going to do the job when the tank is next empty, if I have all of the hoses in time. I have all of the ventilation system hoses in hand now. I'll order the fuel system hoses and other items next week.

The fuel tank is 3/4 full, so I probably have 2-3 weeks until it's empty and I can do the job with only a couple gallons in the tank. If I push it to the limits, I can JUST get 300 miles out of a tank of fuel.

Also, FYI, the rubber gasket that seals the fuel strainer to the tank is NLA from MB. I'm going to need to find a substitute for this piece of rubber. Perhaps a newer G-wagen model seal would do the trick, given that the fuel tank was used on all G-wagens until relatively recently.

Ha! Heavy, but your fuel is a little cheaper, I think. We're at 2€ a litre.

But I did get 820 Km before the yellow light came on when we got to Southampton in the UK from the Dordogne. Or 25.3 miles to one of your gallons.

7.6€ for a US gallon. 8.3 ish $. Misery.

R

 

[gerryvz]

Following up on the original premise of this post, I have decided to replace all fuel lines on the G320. This is starting with the fuel ventilation system lines attached to the fuel tank, as a starting point. I am starting with this, because an inspection of these lines last year, indicated that several of them have cracks.

To that end, I recently ordered the following hoses and items:

• fuel pump - 003 091 53 01 ($125.00)
• fuel tank vent valve - 000 476 22 32 ($74.10)
• short line from fuel sender to breather line - 140mm - 916030 000526 ($26.65/meter)
• short line from top of tank to breather line - 463 476 50 26 ($37.25)
• line from breather line to filler neck - 560mm - 916030 000526 ($26.65/meter)
• line from top of tank to filler neck - 420mm - 916030 000526 ($26.65/meter)
• line from filler neck to vent valve first part - 125mm - 230 476 87 26 ($24.70/meter)
• line from filler neck to vent valve second part - 460 476 48 26 (NLA from MB) - purchased NOS hose from Australia
• line from vent valve to breather pipe - 460 476 36 26 ($20.80)
• line from vent valve, capped - 1060mm - 007 997 61 82 ($3.77/meter)

Next up (ordering next week) will be a replacement of other fuel lines and system components:

• short line from fuel tank to fuel pump - 463 470 00 75 - now available again ($100.10)
• line between fuel return hard line and fuel tank - 461 476 02 26 ($33.80) - 2 required
• line between fuel pump and fuel tank - 463 470 03 75 ($88.40)
• fuel feed line from feed hard line to engine - 463 476 14 26 (NLA from MB)
• fuel return line from engine to return hard line - 463 470 07 75 (NLA from MB)
• fuel line from fuel filter to fuel feed hard line - 463 470 01 75 ($55.25)
• fuel strainer - 463 470 03 06 ($156.00)
• fuel level sender - 009 542 67 17 ($157.30)

For the two NLA lines (which are the immediate feed and return lines that attach to the engine from the under-body hard lines), I will have to have them made up by a custom hose shop, supplying the original lines as models and hopefully providing MB fuel hose of the appropriate diameter that they can cut to length to create the new lines.

I am going to create a two-part HOW-TO on the replacement of the fuel ventilation system (Part I), and the replacement of the fuel delivery system (Part 2). This will entail removing the fuel tank, replacing the fuel pump, fuel strainer, and fuel sender from the tank, cleaning the tank, and then removing and replacing all hardware.

The fuel level sender is in good operating condition, so it will likely just be cleaned and re-installed. I will likely replace the fuel pump (retaining the original pump as an operating spare), and will replace the fuel strainer as a matter of course.

The fuel pump is the same part as the units that are used in the latest E500s employing the single fuel pump (I believe it's a Pierburg pump), as well as other later W124s such as the E320, as well as the SL600 and various 190Es.

All of the hoses and items in the first list above have now been recieved. Interestingly, the fuel pump is a Bosch unit, not Pierburg as I thought it would be. Both the fuel pump and the fuel tank vent valve are made in the Czech Republic.

I'm going to try to get this job done sooner rather than later -- perhaps over the July 4th holiday. In the meantime, I'm going to put in the order for the other fuel lines tomorrow (Friday).

Here are the diagrams for the fuel tank ventilation system, and for the fuel lines, for my G-wagen variation (463.231). Most 1990s G-wagens (perhaps excepting diesel models) should be the same, or very similar.

In the second diagram, it shows a fuel cooler at the bottom left of the diagram. My G-wagen does not have this installed; rather it is installed in G-wagens starting several hundred after mine. The fuel cooler is shared with W140 models, interestingly.


Also my G-wagen, because it has the Webasto pre-heater installed, has a SECOND auxiliary fuel pump that pushes fuel from the fuel tank to the heater underhood. I suppose I need to replace this set of fuel lines. The pump and most fuel lines are available, save for one line (#113 in the diagram) that is 3.5 meters long, which is NLA. I guess I will need to find a suitable substitute for this line. The auxiliary fuel pump is $332.80, discounted.

 

[rayhennig]

the fuel pump is a Bosch unit, not Pierburg

So are my 2 pumps.

R

 

[gsxr]

Early-style pumps with removable check valve are made by Bosch.

Late-style pumps with integrated (non-replaceable) check valve are made by Pierburg, these pumps are longer, and smaller diameter.

They are different designs internally. Early are loud, late are nearly silent. The most recent Pierburg that I received is now made in China (previously Poland). Pics here. The late style was phased into 124 production approximately in early 1995 calendar year. Dunno about G-wag production.

 

[rayhennig]

Also, FYI, the rubber gasket that seals the fuel strainer to the tank is NLA from MB.

I just checked mine and the rubber gasket is included with the strainer - MB original part.

R

 

[gerryvz]

I just checked mine and the rubber gasket is included with the strainer - MB original part.

R

That's really good to know. But if one wants to purchase the gasket as a separate part, it is NLA. This is now often the case with these types of parts.

 

[rayhennig]

But if one wants to purchase the gasket as a separate part, it is NLA.

Would a good quality (nitrile? - I'm guessing here) generic o-ring do the trick? I can't imagine why not.

But what do I know?

R

 

[gerryvz]

I'm sure there are other o-rings/seals from other fuel level senders that could also be substituted, as well.

FYI, the fuel level sender gasket is also NLA from MB - again a part that can probably be used from another model.

 

[rayhennig]

I'm sure there are other o-rings/seals from other fuel level senders that could also be substituted, as well.

FYI, the fuel level sender gasket is also NLA from MB - again a part that can probably be used from another model.

On a completely different subject, we searched for a front roll bar for a W201. MB quotes were in the region of 650€, around 6 months ago. I did the same search yesterday and my usual MB parts supplier quoted 150€. 200€ for another but I've no idea of the difference.

My son's going to check with his friendly (20% discount?) MB parts guy in Angouleme.

We await with interest.

RayH